Industrial Utility Efficiency    

Industries

In a strategic approach to improving its management of compressed air, the company initiated an upgrade of its compressed air system at its Midway plant. In so doing, SumiRiko Tennessee saves 2.1 million kWh and $100,000 in energy costs per year at the plant.  Additionally, lower energy use resulted in the reduction in CO2 of 800 tons per year. With a utility rebate, the project paid for itself within two years.

Auto

The project, which also involved the addition of a booster air compressor and receiver tank – along with the installation of an important pressure control valve – gives the automaker the ability to run fewer centrifugal air compressors during peak production. In so doing, the plant saves nearly 6.1 million kWh and more than $600,000 per year in energy costs. The project also qualified for a $369,374 rebate from the local utility, resulting in a six-month project payback – all while improving system reliability.

Bulk

Reverse pulse type dust collectors often represent a challenge to compressed air energy efficiency, and sometimes throw a wrench into the works by causing huge air pressure fluctuations, high transient flows and just plain large leaks. This article discusses this type of dust collector, often installed in food processing plants, and gives some real-life examples of problematic installations. Some suggested measures are mentioned to ensure your dust collectors keep running in a trouble-free manner.

Food

As a leading North American bakery company Weston Foods ensures its numerous facilities productively and cost-effectively produce high-quality baked goods. But it doesn’t stop there. It goes the extra mile to optimize and manage its utilities to conserve energy and protect the environment.

Medical

The University of Manitoba Bannatyne Campus, Canada, upgraded its compressed air system to include variable speed drive (VSD) air compressors and the use of internal heat-of-compression (HOC) drying, replacing oil-free air compressors and refrigerated dryers that reached the end of useful life. In doing so, the campus reduced annual energy consumption by 15%, improved the quality of the compressed air to modern day instrument air standards and gained additional compressed-air capacity. The local utility also awarded the medical campus an incentive of $13,500, offsetting the cost of the initiative.  

Metals

The steel mill in this article is a rolling “minimill,” a facility that melts scrap recycled steel and produces rebar for the construction industry. It fits in SIC code 3310. There are many plants like this all over the world, providing an environmentally sound service and product for their local community. They recycle waste steel from local sources and support local infrastructure projects with rebar, using electricity generated locally.

Paper

Experienced auditors become wary when they see desiccant dryers installed in customers’ plants. These dryers are required when a plant needs instrument-quality compressed air, or when compressed air piping is exposed to freezing temperatures. However, while desiccant dryers can gain this level of quality, the energy cost of stepping up from a dewpoint of 35 oF to a level of -40 oF increases quite considerably. To attempt to reduce the energy costs of drying to these low levels, heated blower desiccant styles may be used. This article describes three common desiccant dryer types, as well as some experiences, good and bad, with heated blower types.

Pharmaceutical

A pharmaceutical plant, has had a compressed air assessment performed on two plant systems.  The studies uncovered poor compressed air production efficiency, high air dryer loss, and problems with high flow compressed air uses negatively affecting plant pressure. The plant implemented energy efficiency measures, on the two compressed air systems, saving 46 and 64 percent in energy costs respectively.

Plastics

The plant produces both molded and blow molded plastic parts on a 5 day per week, three shift schedule. Production and maintenance sometimes occurs on weekends, occasionally requiring the air compressors to run on a 24 x 7 basis so the practice was to leave the compressed air system always pressurized. The system consisted of three modulating lubricated screw compressors one sized at 150 hp and the others 125 hp (3 units), each controlled with their local compressor controllers.

Power

A newly constructed ethanol plant experienced control gap issues shortly after comissioning.  This article discusses the cause of the issue and how the problem was solved.

Printing

The Trinity Mirror Group print works on Oldham is one of the UK’s largest newspaper printers. The nine presses in the facility produce around 1million papers every day, including the Independent, the Daily Mirror and a range of local, regional and sports titles. Printing on this scale does not come cheap in energy terms, however. The plant’s annual electricity bill is in the order of £1.5millon. With energy prices on the rise, and a strong desire to improve environmental performance and reduce its carbon footprint, the plant’s management has recently embarked on a project to cut energy use substantially.

Transit

When the New York City Transit Authority (NYCT) set out to comply with local regulations calling for reductions in energy usage, it leveraged new air compressors for use in transit bus maintenance and repair – and took things to another level by recovering air compressor waste heat to provide hot potable water for the bus depot. The air compressor and heat recovery system, installed in spring 2017, is on its way to helping NYCT achieve the best energy savings possible.

Wastewater

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.
As a leading North American bakery company Weston Foods ensures its numerous facilities productively and cost-effectively produce high-quality baked goods. But it doesn’t stop there. It goes the extra mile to optimize and manage its utilities to conserve energy and protect the environment.
Reverse pulse type dust collectors often represent a challenge to compressed air energy efficiency, and sometimes throw a wrench into the works by causing huge air pressure fluctuations, high transient flows and just plain large leaks. This article discusses this type of dust collector, often installed in food processing plants, and gives some real-life examples of problematic installations. Some suggested measures are mentioned to ensure your dust collectors keep running in a trouble-free manner.
In modern and industrial work settings, people spend more than 90% of their time in enclosed spaces, such as warehouses, office buildings and factories. In most indoor environments, the air contains a variety of chemical and microbial particles, commonly defined as indoor pollutants, which can severely affect human health and product quality (1). Industries like food and beverage, medical devices and pharmaceutical manufacturers rely on their scheduled compliance testing to confirm the presence or absence of issues in workflow pipelines that are detrimental to the daily output and safety of the product.
The project, which also involved the addition of a booster air compressor and receiver tank – along with the installation of an important pressure control valve – gives the automaker the ability to run fewer centrifugal air compressors during peak production. In so doing, the plant saves nearly 6.1 million kWh and more than $600,000 per year in energy costs. The project also qualified for a $369,374 rebate from the local utility, resulting in a six-month project payback – all while improving system reliability.
A chemical packaging facility had done everything right when they last upgraded their compressed air system a few years ago. They installed a Variable Speed Drive (VSD) air compressor and implemented other energy efficiency measures, but plant expansions caused increased system demand, which exceeded the capacity of the system. The packaging lines were now seeing low pressure, causing shut downs in production. And projections showed plant demand would increase even further.
With an eye toward strengthening its competitive edge, GKN opted for a new approach for the compressed air it uses to power metal molding machines in addition to a variety of other applications at its manufacturing facility. After careful analysis and planning with the Total Equipment Company located in Coraopolis, Pennsylvania, GKN opted to move beyond its aging compressed air system – and instead – outsource compressed air as a utility. Doing so allowed it to free up valuable floor space, while also achieving peace of mind since it can now count on a fixed cost for a reliable compressed air supply for years to come.
Often, multiple centrifugal air compressors are set up to simply react to air demand, which requires the system to not only meet the new demand, but also make up for air depleted in the main header. This typically results in too much supply, which results in bypassing the air to atmosphere. The result is wasted energy use.
In terms of compressed air systems, it’s not unusual to see a plant with 10 to 15 air compressors, each of which is rated to provide 3,000 to 4,000 scfm of air. The air is used for everything from moving product, to powering pneumatic tools, pumps, and fans, to cleaning. There are easily 1,500 pneumatic control valves at a single plant.
Plant personnel had experienced ongoing problems with its process grinder performance due to unstable compressed air pressure. This created potential problems in terms of product quality. Grinders do not work properly without the proper pressure. Additionally, plant staff wanted to address these concerns, prior to a proposed 30% increase in production, and suggested raising the header pressure from the current operating pressure of 98 psig to 125 psig. The thought behind this was if the pressure from the header to the grinder process was dropping to 63 psig, then raising the pressure to the process would give the grinders enough pressure to work through higher peak production times.  
The steel mill in this article is a rolling “minimill,” a facility that melts scrap recycled steel and produces rebar for the construction industry. It fits in SIC code 3310. There are many plants like this all over the world, providing an environmentally sound service and product for their local community. They recycle waste steel from local sources and support local infrastructure projects with rebar, using electricity generated locally.