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Strategies to Reduce Compressed Air Costs on the Demand Side Nipsco Symposium Merrillville, Indiana October 8, 2014

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Page 1: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Strategies to Reduce Compressed Air

Costs on the Demand Side

Nipsco Symposium

Merrillville, Indiana

October 8, 2014

Page 2: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

The Best Opportunities to Improve Efficiency

and Reduce Costs of Your Compressed

Air System on the Demand Side

Compressed Air System Efficiency

Page 3: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Compressed Air is NOT Free

Page 4: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Compressed Air vs. Electric

Page 5: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Energy Cost Calculation

Page 6: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Artificial Demand

Page 7: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Operating Cost Reductions

Page 8: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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The Basic Rules

Page 9: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Bottling Plant Before Compressor

Room Piping and Design

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Page 10: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Bottling Plant After New Design and

Materials

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Page 11: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

After with 4” Aluminum Alloy

Reusable Piping

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Page 12: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Bottling Plant Economics

Page 13: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Types of Venturi Vacuum Generators

Page 14: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Venturi Vacuum Generators

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Page 15: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Venturi Vacuum Generators

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Page 16: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Venturi Vacuum Generators

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Page 17: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Venturi Vacuum Generators

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Multi-stage Co-axial are more efficient than Single-stage

Page 18: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Air Cylinder / Dual Pressure

Regulators

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Page 19: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Air Cylinders

Page 20: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Blow-off Air

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Page 21: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Low Pressure Blower Generated

Blow-off Air

Use Low Pressure Air Whenever Possible!

Page 22: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Blow-off Air

Page 23: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Shut off blow-off air when not needed

Blow-off Air

Page 24: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Blow-off Air

Replace blow-off air with Mechanical

Page 25: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Blow-off Air

Page 26: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Control Cabinet Cooling

Do you actually

need cabinet

cooling?

Page 27: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Heat Pipe Cabinet Cooling

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Page 28: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Vortex Tube Refrigeration

Cabinet Cooler

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Page 29: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Thermostatic Automatic Shut-Off

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Page 30: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Thermoelectric Refrigeration Cabinet Coolers –

Peltier Cooling

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Page 31: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Cabinet Cooling

Page 32: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Optimizing Air Operated Double

Diaphragm Pumps

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Page 33: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

AODD Comparison

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Page 34: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Air Operated Double Diaphragm

Pumps

Page 35: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Air Vibrators

Page 36: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Air Motors

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Page 37: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Air & Electric Driven Motor Hoists

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5,000 Lb. Class Hoist

Page 38: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Air Motor - Driven Mixers

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Page 39: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

Compressed Air Leaks

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Page 40: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

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Compressed air leaks -- 60 leaks at 280 cfm

Estimated cost to repair $6,000

Recoverable energy savings $28,000/year

Compressed Air Leak Examples

Page 41: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

41

Compressed Air Leak Example

Page 42: Strategies to Reduce Compressed Air Costs on the ... - … Compressed air leaks -- 60 leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year Compressed

THANK YOU for this Opportunity to Present

Hank van Ormer

Air Power USA, Inc.

740.862.4112

[email protected]

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