Industrial Utility Efficiency    

Technology

Among the many “systems” plant personnel are concerned with, the compressed air system often provides the biggest opportunity for improvement and overall savings. There are many manufacturers and several air compressor technologies to choose from. Reciprocating or rotary? Fixed speed or variable speed? Oil flooded or oil free? Single-stage or two-stage technology? It’s enough to make anyone want to run and hide!

Air Compressors

Properly sizing a compressed air system can help determine if your facility has enough air to adequately supply your production equipment. Designing a cost effective system that minimizes any interruptions to productivity requires thoughtful planning and design. Typically, the desired outcomes of such a system focus on stable pressure and efficient operation, though it is important to note that each of these elements requires a unique solution. This article will provide guidance in proper selection considerations and suggest when a centrifugal air compressor may be ideal for your needs.

Air Treatment

Air compressors can produce a lot of water. Humidity in ambient air, once compressed, results in much of this water falling out, which we know as condensate. On a warm and humid summer day with inlet air temperatures of 80 oF, a 75-horsepower (hp) air compressor running fully loaded can produce over 25 gallons of condensate in just one eight-hour shift, with another five gallons being produced once the compressed air is sent through a dryer. The compression process allows for the air, water vapor, and lubricating fluids to mix. Once the condensate leaves the system, trace amounts of lubricant travel with it. This condensate should be processed through an oil-water separator before being discharged to groundwater or wastewater treatment plants.

Blowers

The plant upgrades, in combination with a progressive management strategy, allows the plant to consume less energy and reduce its reliance on outside contractors for biosolids removal, resulting in total operational savings of approximately $60,000 per year.  The plant is also positioned to efficiently manage the area’s wastewater for decades to come.

Compressor Controls

Companies will experience periods of increased production, as well as periods of slower or stopped production. It’s the nature of being in business. Understanding the implications of these business shifts for compressed-air installations (the powerhouse behind a facility’s production) is key for ensuring that air compressors remain functional and efficient. Here are guidelines to ensure your facility’s compressed-air system operates at top performance, no matter the speed of production.

Instrumentation

Like any system, to properly manage compressed air equipment some measurements have to be taken. Typically, some sort of data logging equipment is installed to measure various pressures, amps or power, flow, and sometimes temperatures and dewpoints. Placing this equipment on a system is like putting an electrocardiograph machine on a human heart, the heartbeat of the compressed air system in a plant can be analyzed to determine if everything is normal or if there is a problem, all without interrupting the system. 

Pneumatics

In this article, we discuss problems associated with static electricity in industrial manufacturing operations and how to effectively address them. At the atomic level, materials have a balance of positively charged protons in the nucleus and negatively charged electrons in the shell. Balance requires the same number of each.  A static charge occurs when that balance shifts due to the loss or gain of one or more electrons from the atom or molecule. The primary mechanism for this loss or gain, among several possibilities, is friction.

Vacuum

It’s one thing to move materials during the production process, but when it’s a finished product on the packaging line, choosing the right material handling system is essential. Getting it wrong results in squandered production time when product loss occurs, and wasted raw materials.

Cooling Systems

As a result of compressed air awareness training and a focus on energy management, two facilities in different parts of the world have reduced their compressed air demand substantially by removing vortex style cabinet coolers from some of their electrical panels and reworking the cooling systems.  These facilities were previously unaware of the high cost of compressed air and how much could be saved if other methods of cooling were used. This article describes some of their efforts in demand reduction.
Your industrial compressed air and gas system constitutes a major investment and a significant contributor to operating efficiently and productively. Keeping your air compressor in peak condition should be high on your list of maintenance activities. Fortunately, these industrial workhorses do not require a lot of costly or time-consuming resources to keep performing year after year. Still, performing a few routine checks, tests, cleanings, and adjustments will go a long way toward keeping your air and gas compressors in fine condition, generating a host of benefits.
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.
Air compressors need to be matched to load effectively and efficiently. If the air compressors’ range of variation can’t be matched to the system variation, instability and/or inefficiency can result. This article discusses the problem when it isn’t matched, which is called “control gap” and what to do to avoid it.
Have you ever wondered how to stay “in control” of an engineering organization with a fixed staff and a varying workload, where the engineers all have a mind of their own? “Herding cats” is what they call it.  Of course, that’s normal, right? Well, controlling multiple centrifugal air compressors is pretty close to that model, which can lead to a condition known as “control gap.”  This article discusses the reasons for control gap with centrifugal air compressors and solutions to help avoid it.
We manufacture and market a full line of low- and medium-pressure piston and screw air compressors, as well as air dryers, air tanks and accessories. Ozen Air Technology is a subsidiary of Ozen Kompresor based in Konya, Turkey. Our company has been manufacturing air compressors and related equipment for more than 50 years. In 2018, we expanded into North and South America with an operation in Charlotte, North Carolina, which is exciting for us given the opportunity we see.  
While many businesses strive to plan, install and maintain a compressed air system that fulfils the company’s specific needs, I’ve found that implementing compressed air best practices not only accomplishes specific goals, but also results in time-tested advantages that aid in the overall business and production goals of the organization.
There is usually a deep feeling of pride welling up inside the designers and installers after completing the installation of a new compressed air system, especially if it starts up and works perfectly. But what happens after a few years, are things as perfect as at the start? This is a question with an answer that very few people know for their system. This article describes some interesting experiences with a food products company at two plants where compressed air assessments of optimized systems done a few years after the system upgrades showed problems.
The Best Practices EXPO & Conference held from October 13-16, 2019 in Nashville, Tennessee, saw a significant increase in attendance growing by 15 percent to 850 attendees from 20 countries. End user (factory personnel) attendance grew by 60 percent! The EXPO was also truly international showcasing 115 exhibitors from 16 countries and EXPO attendance was free for qualified industry personnel. This SHOW REPORT EXTRA Part 2 complements our 2019 Best Practices EXPO & Conference Show Report and the Show Extra Part 1 Report. 
This story begins in Coburg, Germany in the year 1919. Coburg was first mentioned in a monastic document dated 1056, but to speed forward almost nine centuries, Coburg would join the Upper Franconia Region of Bavaria in 1920 where it remains today. Back here in 1919, the United States passed the 19th Amendment allowing women the right to vote and Pancho Villa was attacking Juarez, Mexico. So it was in 1919 that in Coburg a gentleman named Carl Kaeser Senior would open a small workshop producing parts for the early automotive industry, along with gear wheels and special machines for the glass industry.
High accuracy of multiple measured parameters is critical for the development of a trusted compressed air system baseline audit. The same is true for follow-on performance validation after system improvements have been implemented. The use of data acquisition systems using Modbus-interfaced transducers can aid auditors in achieving a thorough and highly accurate system performance assessment.