Industrial Utility Efficiency    

System Assessment

“A single ¼-inch leak in a compressed air line can cost a facility from $2,500 to more than $8,000 per year. Locating and fixing leaks will result in significant savings depending on pressure requirements and energy costs.”

Compressor Controls

It was early summer, the air compressors were above the production floor on a mezzanine, and temperatures were heating up both outdoors and indoors. The compressed air system was comprised of three 500-horsepower centrifugal air compressors, and one 350-horsepower variable speed drive oil-free rotary screw air compressor.

Piping Storage

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.

End Uses

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.


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.

Air Treatment/N2

Often when you mention heat of compression the first thought generally relates to HOC desiccant dryers, which are also an under-applied opportunity for heat recovery. However, there are many other heat of compression recoverable energy savings opportunities in all compressed air and gas systems. This article reviews many opportunities in energy heat recovery and provides answer to commonly asked question.


Awareness and interest in leak detection only continues to grow thanks to a number of factors. What we have seen over the last 20 years is a more sustainable way of thinking, established international energy efficiency standards, reliable leak detection technology, and best practices to implement leak detection.


The advent of manifold-mounted, plug-in pneumatic valves has been a boon for machine builders. It allows them to mount complete valve packages in a safe and secure location on a machine. Using a D-sub connector, serial interface module, or similar single-point wiring system, all of the electrical control outputs can feed into one location on the manifold, greatly simplifying the wiring.

Vacuum Blowers

Every municipality and utility is facing the reality of rising energy costs. In 2010, the Town of Billerica, MA, which is located 22 miles northwest of Boston with a population of just under 40,000 residents, engaged Process Energy Services and Woodard & Curran to conduct an energy evaluation of the Town’s Wastewater Treatment Facility (WWTF) and pump station systems sponsored by National Grid. The objective of the evaluation was to provide an overview of each facility system to determine how electrical energy and natural gas were being used at the facility and to identify and develop potential costsaving projects.
Ahresty Wilmington Corporation (AWC) was founded in 1988 and is located in Wilmington, Ohio. Currently AWC employs over 900 people with sales totaling $192 million. They have grown steadily, all while continuously improving and staying on the leading edge of technology. AWC is a tier-1 automotive supplier servicing their entire customer base in the United States. AWC has established an efficient and integrated production system that incorporates die-casting, finishing, machining, and assembly operation using just-in-time production methods to provide its customers with quality products at a competitive price.
In recent years, we have seen an upward trend of higher production manufacturers wanting to integrate their air gauging quality checks from a stand-alone, outside-of-machine device where the operator is performing a manual check to an automated in-process gauge. There are several reasons for this trend, including higher quality standards, tighter tolerances, as well as running a leaner operation. The benefits are 100 percent inspection of the required geometric callout, as well as handshaking between measuring device and machine to make each piece better than the prior one. It also removes any bad parts.
When a company is considering making an investment of more than a million dollars in system upgrades, it is crucial for them to review all options to get the best return. By exploring energy efficiency impacts throughout the entire compressed air system, vendors can propose projects resulting in both a larger sale for them and increased financial benefits for their customers, while still meeting capital expenditure guidelines. This “best of both worlds” scenario was evident when a foundry in the Midwest was evaluating options for replacing its steam system used to drive the plant’s forging hammers.
EnSave, an energy auditing company based in Richmond, Vermont, recently performed compressed air audits at two facilities of a leading U.S. steel manufacturer. Both plants are mills that melt, cast, and roll steel to produce a variety of products, including: rebar, merchant bar, steel flats, rounds, fence posts, channel bar, steel channels, steel angles, structural angles and structural channels. These products are used in a diverse group of markets, including: construction, energy, transportation and agriculture. Compressed air is provided at 100 psig in both plants for a variety of applications — from optical sensor cooling to pneumatic cylinders for stacking finished products.
Compressed air has moved to higher visibility in the energy conservation field, and the buzzwords abound: “the fourth utility” — “your most expensive utility” — “eight times more expensive than electricity” — “a quarter-inch leak costs $9,000 in wasted energy.” This greater awareness has also produced compressed air auditors that are springing up like summer dandelions. With audits available from many sources, it is important to understand what plant operations, engineers and maintenance managers should expect from a complete audit — or more aptly — a complete air system review.
As a reader of this journal, you are well aware that large compressed air systems often have significant wasted air — often from leaks — that represent tens of thousands of dollars of waste per year. However, it is our experience that the so-called “low-cost” measures identified often go un-repaired, while other more costly capital projects get funded. Why? With an ROI of a half year or less, they seem like IQ tests to many compressed air auditors.
Many thousands of dollars of annual electrical savings are being achieved worldwide using special purge reduction controls on desiccant air dryers. These controls reduce the expensive purge air that must flow through the dryer to regenerate the desiccant beds. But, unexpected problems with these controls can cause hidden problems that can reduce or eliminate the savings.
After more than 25 years in the compressed air industry, it still amazes me that many plant personnel and even those who sell compressed air products for a living don’t fully understand the relationship between flow, or volume (cfm), and pressure (psig). Walk into many body shops or small manufacturing plants, and you will find the compressor operating at an elevated pressure to satisfy the “demand.” If a plant has low air pressure on the production floor, what is the first thing that the maintenance professional does? You guessed it: He or she “jacks” up the pressure on the compressor, not realizing that he or she made the problem worse.
Compressed Air Performance Specialists (CAPS Inc.) is a compressed air consultancy located in Calgary, Alberta. In its most recent compressed air project, the company reduced a 200-hp, multi-compressor system down to a single, 100-hp variable speed drive (VSD) air compressor utilizing 75 hp of compressor energy (kWh), resulting in $70,000 in annual energy savings.
There is a partly true idea floating around some plant maintenance circles that “compressed air is free.” Readers of this journal know that isn’t true. But, what if non-compressed air could be seen as “free?” Is there something we can get for free from nature to reduce the cost of our compressed air? What if lower temperature intake air was nature’s gift? What if all we need is a bit of tin to duct air from a different source?