Industrial Utility Efficiency
Without compressed air monitoring, up to 30% of the compressed air generated goes to waste. This waste occurs for several reasons, including leaks caused by failures at joints and tubes, exposure to vibration and normal component wear, and the suboptimization of machines and devices. Continuous monitoring capabilities allow operators to detect leaks and other anomalies in their early stages. By addressing pneumatic issues before they can grow, companies can reduce compressed air use by 20% to 30%.
Dewpoint is defined as the temperature to which a gas (e.g. air) must be cooled, at constant pressure, for water vapor to begin to condense to liquid water. In other words, when the dewpoint temperature has been reached, the gas is fully saturated with water vapor.
Sitting on his desk the day Brian began his new job as Plant Engineer for Carbo Ceramics’ McIntyre, GA facility was a proposal to purchase a new 150 HP air compressor as a backup machine. The facility already had six of these machines and, yes, all six ran almost continuously.
The secret to success is to understand the nature of what type of leak produces a detectible ultrasound and what does not, along with the techniques that can be used for effective leak identification.
Most facilities don’t prioritize the cost of operating compressed air systems—they just want to get the job done. A recent market study1 found that only 17 percent of compressed air users valued efficiency as a compressed air system management goal. Nine percent were concerned with containing energy costs. Seventy one percent simply wanted to deliver a consistent, reliable air supply.
The NPE2009 international plastics showcase was held June 22-26 in Chicago’s McCormick Place. While attendance was down from NPE2006, the preliminary total of visitor registrations numbered 44,000. Sustainability and energy efficiency was a prominent topic in the booths of exhibitors. Manufacturers of compressed air and injection molding equipment had many developments with Sustainability to show the visitors to NPE2009.
The primary objective of this case study is to illustrate the process in which industrial facilities can qualify for energy incentives on projects that reduce the energy usage of their compressed air system.
This commercial printing facility is located in the Northeastern part of the U.S. Like most facilities, the plant has seen many changes over the years.
Over the last several decades, Air Power USA has reviewed many various types of plastic injection molding operations throughout the U.S.
Compressed Air Best Practices interviewed Paul Lukitsch. Mr. Lukitsch is the Regional Facilities & Energy Manager for Millipore Corporation.
Reducing energy costs and pollution emissions involves many areas within an industrial facility. My studies have found seven (7) key (or common) areas where low cost practical projects can be implemented. Combined, these projects provide savings exceeding 10% of the annual energy spend with an average payback of less than one year.
