Technology

Roxane Laboratories, Inc., a subsidiary of Boehringer Ingelheim Corporation located in Columbus, Ohio, created a world-class air system that generated \$61,314 per year in electrical energy cost savings (1,156,868 kWh), improved productivity and quality, and allowed the successful completion of a significant plant expansion.

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.

Industrial plants are major consumers of water. Water is used in many processes. Sustainability projects focus on reducing the consumption of water and the energy-costs associated with cooling water so it may be effectively used.

This aluminum mill spends \$369,000 annually in energy costs to operate their compressed air system. This system assessment recommends actions reducing annual energy costs by \$120,000 and improving productivity and quality by delivering clean, dry compressed air.

Desiccant dryers are commonly used to bring the pressure dewpoint well below freezing (commonly -40°F) in order to prevent moisture from precipitating in the compressed air system and production equipment.

Compressed air dryers are important items to consider when evaluating the efficiency of a typical compressed air system. One of the keys to optimal system operation is ensuring the air is only dried to the level required by the actual needs of the facility.

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.

This article reviews two major processes in paper mills: compressed air quality and air compressor cooling.  The central air compressor room was expanded and relocated at the largest privately owned paper mill in Canada.  The compressor space was required by a plant expansion, which would occupy the original compressor space for increased production.

Compressed Air Best Practices® interviewed Mr. Sid Van der Meer and Mr. Terry Nickel from Northwest Equipment Ltd in Airdrie, Canada.

There are many applications which require a low horsepower compressor built with the technology that has been proven in larger compressors. Often these situations are not addressed well by the general compressor industry.