Technology

The U.S. Department of Energy estimates that air compressors use as much as 10% of all electricity generated in the United States. Further, the DOE calculates that as much as 50% of this energy is wasted. Compressed air leaks alone account for 25-30% of compressed air use.

One of the many tasks in assessing a compressed air system supply side is to analyze the air treatment system for appropriateness and efficiency. Most compressed air systems have one or more air dryers in place to remove the water vapor contained in the compressed air produced by the system air compressors. If there is no air dryer, the normally hot saturated air produced by the air compressors will cool in downstream system components, and condensed water will form in pressurized system pipework.

Nitrogen, an inert gas comprising 79% of the atmosphere, can be distilled from ordinary air. However, companies that use this product in their everyday operations know that it’s not quite that simple and much more expensive than the stuff we breathe. The primary means of obtaining nitrogen for industrial use is to transport it onsite in liquid form, which must be shipped and stored at cryogenic temperatures. But, really, what’s the point of turning nitrogen into liquid for shipping, transporting it to where it’s used, and then turning it back into gas?

The concept offers new possibilities for generating positive pressure or vacuum in a variety of applications. “By applying screw compressor technology to low-pressure air compression, we’ve greatly improved efficiency,” said Pierre Noack, President and CEO of Aerzen USA. The Delta Hybrid has seven patents or patent applications, making it one of the most innovative products in compression technology.

Any time you troubleshoot a large motor drive, you run the risk of both electric arc and electrical shock. Arc blasts are less frequent but deadly. They’re most commonly caused by a dropped wrench or other tool that lands across high-energy bus bars in an open cabinet. This kind of short circuit is upstream of protective fuse links and lets loose thousands of amperes of fault current.

The Hoffman U.S. Machinery Division was established in 1905 outside of East Syracuse, New York. The initial product was an exhauster for the dry cleaning industry — pulling a steam vacuum across the garments. The Company grew and soon after began discovering industrial applications for their technologies. After the war period, during which Hoffman manufactured ball bearings and operated it’s own foundry, the company began discovering new industrial markets for it’s products. A significant part of their business was in the wastewater treatment industry.

Production and quality engineers in industries like the food & beverage, pharmaceutical, semiconductor, and chemical sectors have established internal specifications for oil-free compressed air. The product spoilage and safety issues at risk make oil-free compressed air an absolute necessity in certain processes.

Many times, the hierarchy of making improvements in your compressed air system will begin with the larger equipment. If your compressor is outdated, inefficient or sized improperly for your plant, the cost of replacing it may scare you away from proceeding down the efficiency path. It is also typical to first concentrate on updating the controls of a compressor to best match peak demands and lulls in the need for air and, while this is a very good step to take in your overall plan of attack, it can also burden your budget.

Most P.E.T. bottle-blowing machines require anywhere from 550 psig (38 barg) to 580 psig (40 barg) and an air flow of 247 cfm FAD (420 m3/hr) to 3700 cfm FAD (6290 m3/hr). The air compressor technology used most prevalently for this application is the double-acting, oil-free, water-cooled, reciprocating air compressor. With the higher pressures and air flows that are required, the P.E.T. bottle blowing market is a strong niche market for the double-acting oil-free reciprocating (piston) compressors.

Several days prior to our visit, during a cold winter evening, the lead air compressor in one mechanical room tripped off (apparently due to a fouled intake filter and low air flow through the machine). A crucial situation then developed: The "stand-by" unit did not start. Maintenance folks had to be called in to get a compressor running. That delay caused low plant air pressure, production curtailment and some defective product. They had yet to determine the conditions that caused the "no-start".