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Rod Smith, Editor, Compressed Air Best Practices

Magazine Mary Bentsen, Education and Training Coordinator

SAIC, an Ameren Illinois ActOnEnergy Partner

Advanced Trends in Compressed Air Best Practices

March 6, 2013

Practical Items

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Quiz Questions: What do you already know about advanced trends in compressed air best practices?

1. Which of the following is an energy efficiency system assessment that has a good return on investment?

2. What is the amount of the ActOnEnergy implementation incentive provided for energy savings achieved by an eligible compressed air retro commissioning project?

We Thank our Board Members for providing this information!

2013 Editorial Advisory Board Energy Conservation Managers • Eric Battino – PepsiCo • Briggs & Stratton • Archer Daniels Midland • Saint Gobain • Ball Corporation • Visteon • Honda of America • CalPortland Cement

Compressed Air Best Practices® Magazine

Mission To help create energy-efficiency projects related to compressed air systems. • Editorial focus on detailed energy-efficiency SYSTEM ASSESSMENTS with good ROI’s

• How to reduce flow and pressure • How to measure • Filter out “green washing” • How to apply technology

• Air Compressors • Air Dryers • Piping • Pneumatics • Blowers & Vacuum

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Presentation Topic Advanced Trends in Compressed Air Best Practices

Phase 1: Fundamental Energy Analysis Has Already Been Done • Box Diagram of compressed air system • Data-log air compressors-establish baseline energy consumption • Optimize compressor controls

Advanced Trends in Compressed Air Best Practices

Phase 1: Fundamental Energy Analysis Has Already Been Done • Box Diagram of compressed air system • Data-log air compressors • Optimize compressor controls

Plastek CPD Erie, PA July 2005

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Unit 1 Unit 2 Unit 4 Unit 5 Unit 2 Discharge Press Unit 4 Discharge Press System Press

Advanced Trends in Compressed Air Best Practices

Phase 1: Fundamental Energy Analysis Has Already Been Done • Box Diagram of compressed air system • Data-log air compressors-establish baseline energy consumption • Optimize compressor controls Key Performance Indicator

Specific Power Objective of 100 cfm/21 kW

Advanced Trends in Compressed Air Best Practices

Phase 1: Fundamental Energy Analysis Has Already Been Done • Box Diagram of compressed air system • Data-log air compressors-establish baseline energy consumption • Optimize compressor controls

Reducing Demand Does NOT Save Energy

WITHOUT the appropriate Compressor Controls

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MEC_SCFMTotal Kw

Flow changes but kW does not change

proportionally

Flow

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Advanced Trends in Compressed Air Best Practices

Phase 2: Measure Air Flow (cfm) to Reduce Demand • Reduce Flow Requirements of Production Equipment • Charge Production Areas for cfm Consumption

• Flow(cfm) measurement to 6 Unitizer Machines,

Verallia Plant (Saint Gobain)

• Establish “Best Practice Flow” for each machine

• Datalog and Monitor the

flow

Advanced Trends in Compressed Air Best Practices

Phase 2: Measure Air Flow (cfm) to Reduce Demand • Reduce Flow Requirements of Production Equipment • Charge Production Areas for cfm Consumption

• Flow(cfm) measurement to 6 Unitizer Machines,

Verallia Plant (Saint Gobain)

• Establish “Best Practice Flow” for each machine

• Datalog and Monitor the

flow

Honda of America East Liberty, Ohio Compressed Air System Evolution • Phase 1 (late 1990’s)

• 5 x 1000 hp, 450 hp trim • Compressor Room kW

and pressure data logging • Plant Pressure 135 psig • Car production: 240,000

autos • Had one $ and kWh

metric for compressed air for whole plant

• Phase 2 (2002-today) • 2 x 1000 hp, 450 hp trim • Monthly compressed air kWh

budgets for each of 4 major production areas – flow meters measure each area like a utility

• Master Compressed Air System Measurement and Management

• Plant Pressure 105 psig • Car production: 240,000 autos

Phase 2: Measure Air Flow (cfm) to Reduce Demand

• Reduce Flow Requirements of Production Equipment

• Charge Production Areas for cfm Consumption

Phase 2 Advanced Trend Shut-down Optimization

• Shutdown Optimization: Airlock on chemical tanks forced a 100 hp compressor to turn on/off during shutdown periods. Purchased a small 5 hp air compressor and disabled the 100 hp. De-centralized, point-of-use solution. Source: Jennifer Meier, Global Energy & Engineering Manager, Visteon Corporation, July 2011 Compressed Air Best Practices Magazine

• Bottling Machines & Packaging Machines: Continue to use compressed air when idle. Solution is to isolate them from compressed air system with valves that close when the machine is turned off.

Phase 2: Advanced Trend Heat Recovery

• Focus on Reducing HVAC and boiler energy costs

• Exhaust air recovery • Compressed air waste heat

(particularly from oil) is an opportunity in most plants to warm process water.

• New standard OEM heat recovery HX make this easier to do

Phase 2 Advanced Trend The Energy Costs of Air Quality

Specifications

Energy Costs Associated with Pressure Dewpoint Specifications

• The ISO 8573.1 Class 2 (-40 °F / -40 °C) specification is costing hundreds of millions in energy costs due to desiccant dryer purge air and heaters • Test whether Class 4 Air Quality (+38 °F / +3 °C) is adequate for 75% of the facility

Phase 2 Advanced Trend Energy-Efficiency in Different Pressure

Sub-zones of a Facility

Stretch Blow Molding Facility • ½ liter water bottles being

blown at 20 bar (294 psi) due to reduced plastic content

• Carbonated soft drinks and juices in <1 liter containers blown at 30 bar (441 psi)

• CSD’s in >2 liter containers blown at 35 bar (515 psi)

• Plant air at 100 psi

Stretch blow molding facilities spend $1-3 million annually on compressed air – with a 30% energy savings opportunity if they can manage pressure and pressure drops effectively.

Phase 2 Advanced Trend Engineering for Lower Plant Pressure

Ball Corporation • North American Operations

• 20 Aluminum Can Plants • 15 Food Container Plants • Compressed air is #1 user

of electricity accounting for 20-30% of total use

• System assessments have reduced compressed air energy costs from $50 to $40 million per year (over the past 5 years)

“We believe in engineering solutions into our processes to keep lowering pressure. A can printer used 125 psi – now we use a 2-1 amplifier to support the two-inch cylinder (with a 6 inch stroke) needing that pressure.”

- Doug Barndt, Manager, Demand Side-Energy-Sustainability,

Ball Corporation

Phase 2 Advanced Trend Optimizing Pneumatics in OEM

Equipment

Pneumatic Circuit Assessments

• Replace 2 position valve with a 3-position valve

• Idle flow is reduced from 75 cfm to 25 cfm – on 20 MACHINES

• Undersized Tubing Diameters, Valves and Cylinders Creating Pressure Restrictions

• Air Leaks at FRL’s

3-position valve does not use air when machine is idle

Stock Image: Unitizing & Palletizing Machine

Phase 2 Advanced Trend Purchasing Specs to include Energy

Costs in OEM Production Equipment * kW

* Pressure (psig) * Idle Flow (scfm)

* Production Flow (scfm)

Pneumatic Circuit Assessments

• Establish Best Practice Flow • Actuators and Regulators creating

significant pressure drops • Compressed air leaks in FRL fittings • Pressure drop due to undersized

pneumatic circuits/tubes

Unitizing Machine Before

Unitizing Machine After

Advanced Trend Blow-off Air Optimization

Bottlers, Bakers, Metalworking and Printers Blow-off Air

• Replace 100 psi Blow-off Air applications with 3-5 psi blowers

• High efficiency Air Nozzles

• Bottle Drying in Beverage Industry • Commercial Bakeries removing crumbs

from bread • Metalworking removing metal scrap

from product • Printers keeping paper separate • Blower implementations then create

need to re-assess supply side air compressor controls for specific power optimization

Please Recommend our FREE Print Publication

to your Colleagues.

- Rod Smith, Editor tel: 412-980-9901

rod@airbestpractices.com www.airbestpractices.com

Phase 2 Summary • Measure air flow (cfm) • Shutdown optimization • Heat recovery • Air Quality Specification • Air Pressure Sub-zones • Lowering Plant Pressure • Optimizing Pneumatics in OEM Production Equipment • Blow-off Air Optimization

The Ameren Illinois ActOnEnergy® Business Program

Over $30 million in energy-efficient cash incentives

ActOnEnergy® Incentives Available

STANDARD

• Lighting

• HVAC/Water Heaters

• VFDs

• Steam Traps

• Leak Survey & Repair

• Specialty Equipment

CUSTOM

• Custom

• New Construction

• Feasibility Study

RETRO COMMISSIONING

(RCx)

• Compressed Air

• Healthcare

• Commercial Buildings

Compressed Air - Retro Commissioning Program Typical Measures

25

• Leaks

• Plant Pressure Reduction

• Controls Tune-Up

• Zero-Loss Drains

• Inappropriate Uses

Compressed Air - Custom Program Typical Measures

26

• Air Management System • Flow Controller

• Sequencer

• Air Receiver Tank

• Variable Speed Drive Compressor

• Base-load/Trim

• Air Dryer Upgrades

Compressed Air - Leak Survey & Repair Program Typical Measures

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Leak Detection & Leak Repair

Compressed Air - Feasibility Study Program Typical Measures

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• Air Management System • Flow Controller

• Sequencer

• Air Receiver Tank

• Variable Speed Drive Compressor • Baseload/Trim

• Air Dryer Upgrade

Ameren Illinois ActOnEnergy

Energy

Advisors

Find a Contractor Click here to find a

Contractor who is an ActOnEnergy Program Ally.

• Website: ActOnEnergy.com/Business

• Phone: 1.866.800.0747

• Fax: 1.309.677.7950

• Email: ActOnEnergyBusiness@Ameren.com

Resources

Quiz Questions: What did you learn about energy efficiency advanced trends in compressed air best practices?

1. Which of the following is an energy efficiency system assessment that has a good return on investment?

2. What is the amount of the ActOnEnergy implementation incentive provided for energy savings achieved by an eligible compressed air retro commissioning project?

v

Questions?

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