Industrial Utility Efficiency    

Technology

It is becoming a “best practice” to install a variable frequency drive (VFD) air compressor whenever one is replacing an old air compressor.  As a result, real systems have fixed-speed and VFD air compressors, mixed.  I have observed several VFD compressor sizing methods.  In my last article, I referred to a common method: size one VFD compressor for the whole system.  This can work.  However, if it doesn’t meet a higher peak demand, one or more of the old compressors will be started, and a mixed system results.   Another method is to replace a compressor with the same size, but with a VFD.  If the compressor that was replaced is large, a big VFD is installed.  If small, a small one.

Air Compressors

There are many choices of compressor technology and types of controls that can be used for variable demands. Some examples are rotary screw compressors with inlet valve control: variable speed drives: load/unload control; or centrifugal compressors with variable inlet guide vanes. However, in many cases, the efficiency of the overall compression process can be reduced significantly during lower flow demands, leading to more power per unit of air flow being delivered. It is very important to evaluate different available options and see how a plant can run most efficiently.

Air Treatment

Compressed air is dried to prevent condensation and corrosion which can disrupt manufacturing processes and contaminate products. Water is the primary promotor of chemical reactions and physical erosion in compressed air systems. A myriad of desiccant dryer designs have been devised to provide “commercially dry” air, air having a dew point of -40°F or less, to prevent corrosion.  Desiccant dryers use solid adsorbents in granule form to reduce the moisture content of compressed air.

Blowers

High speed bearing technology is applicable for aeration blowers operating at much higher speeds than the typical 60Hz, 3600RPM for cast multistage units. High Speed Turbo (HST) units are usually single stage (though some utilize multiple cores) and rotate from 15,000 to 50,000RPM. At such high speeds, standard roller bearings cannot offer the industry standard L10 bearing life. Two types of bearing technologies have come to dominate the wastewater treatment market for these types of machines: airfoil and magnetically levitated. Often the two technologies are compared as equals, however, in many significant ways they are not.

Compressor Controls

Load-sharing is an important part of a multiple centrifugal-compressor master control system. It minimizes blow-off based on the available turn-down. In addition, remote start-stop saves more energy if load floats between different ranges. Finally, adding a screw compressor and implementing a hybrid control system might save the most energy and provide the best back-up. In any case, a well-instrumented system allows engineers and operators to assess, optimize and tune the system.

Instrumentation

Compressed Air Best Practices® Magazine interviewed Mr. Warwick Rampley, the National Sales Manager for Sydney (Australia) based, Basil V.R. Greatrex Pty Ltd. It’s not every day one is asked to deliver a system able to provide both a reliable compressed air dew point of -80°C (-112°F) and high purity nitrogen.  We work with some excellent technology suppliers and have engineered a rather interesting system.  Although our firm was founded in 1919, this application is one of the most demanding we’ve encountered. Basil V.R. Greatrex is a unique company as we focus only on compressed air measurement, compressed air quality and compressed air efficiency.

Pneumatics

The design of wastewater treatment plants is changing, and it has something to do with LEGO® bricks. More specifically, it has to do with how large and complex LEGO structures are built. If you follow the instructions carefully, you build module after module, eventually piecing them together to create a fully functional and cohesive unit.

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.
In our discussions with Stephen Titus and James Bowers, National Sales Manager of Titus Air Systems, we talked about several examples of how The Titus Company provided custom-engineered solutions to various customers. The diversity and complexity of these jobs exemplify how The Titus Company has grown from a small distributorship operating out of a townhome to a thriving compressed air and gas solutions provider capable of tackling highly nuanced applications.
In general, this article focuses on the operating principles of centrifugal air compressors, discussing them in simple terms to provide an understanding of application limitations and opportunities. One primary goal is to define often-confusing terminology, such as “rise to surge,” stonewall and surge,” “mass flow,” and “dynamic compression.” This article is not intended to be an engineering discussion of the various types and designs of centrifugal and other air compressors, but rather, a guideline for deciphering operating curves and understanding general performance.
There are many distributors in the industrial air compressor industry that are very concerned about the future role of distribution—or, more specifically—if there even is a role for distribution in the new business environment. The industry has changed, and doing business in the current environment is very different from what distribution has become accustomed to. You may describe it as a “changing of the paradigm” or “moving the cheese,” but make no mistake—it has changed drastically. There are examples of progressive distributors that have succeeded in managing change and have adapted their business strategy accordingly.
Biogas is an extremely valuable energy source. Originating from biomass, sewage, plants and landfill sites, it is gaining ever-increasing worldwide recognition as a premium source of renewable energy. It is also making a major contribution to the global energy supply mix by replacing existing fossil-fuel sources such as coal, oil and conventional natural gas.
Plug an electrical device into an outlet. Does it work? Great! For some people that’s all that matters. When it comes to compressed air, many manufacturing plants operate the same way. As long as there is enough air, that’s all that matters. But what if cost control also matters to your company? Smart compressed air users may already know how much air they’re producing, but they also want to know how much air they’re using—and whether they’re using it productively. To find out, they’re taking accurate, real-time measurements using flow meters.  
In 1979 I received a call from a business friend that had just purchased his first single-stage base cup blow machine. He was surprised to find out that he actually needed something more than 100 psi of plant air to blow bottles. This was my entry into engineering a polyethylene terephthalate (PET) compressor system. Since then, I have engineered and delivered over 350 systems—from Tobago to Tibet—and many locations in between.
Acrylon Plastics located in Winkler, Manitoba, Canada manufactures an extensive variety of custom plastic parts for a wide range of end use applications. Years ago changes to their production volumes increased the compressed air flows to above what their compressed air system could deliver. As a result the plant pressure would fall to low levels during production peak demands, which negatively affected sensitive compressed air powered machines. In addition to this during light plant loading conditions the air compressors would run inefficiently. Plant personnel tried a variety of strategies to deal with the plant peaks, with the most efficient solution coming as a result of installing VSD style compressors and pressure/flow control.
The beverage industry has been using polyethylene terephthalate (PET) 2-liter plastic bottles primarily for packaging carbonated soft drinks since the 1970s. As that market has grown to encompass bottled drinking water, stretch blow-molding machines continue to produce those plastic bottles. The concept is simple: A pre-form plug is inserted into the blow molding machine heated, and compressed air is injected, “blowing” into the pre-form to create the bottle.
A culture change is in the air at Sullair, a pioneer in air compressor technology, as the company celebrates its 50th anniversary. A global manufacturer of rotary screw air compressors used to power air-driven industrial equipment and tools used in manufacturing as well as the energy, mining and chemicals industries, Sullair operates five manufacturing facilities worldwide.
This is a 130,000 square foot manufacturing, warehousing, application engineering, new product development and customer service center all dedicated to Parker compressed air treatment and chiller technologies. We have 70,000 square feet dedicated to manufacturing, 30,000 square feet to warehousing and shipping, and 30,000 square feet for customer service and application engineering.