AEP Ohio Compressed Air Expo - PDF Free Download

AEP Ohio Compressed Air Expo September 19, 2012 Hank van Ormer John Skelton Air Power USA airpowerusainc.com 1

Topic: Hands on Examples to Reduce Air System Costs (Demo Exhibit) Company: Air Power USA Columbus OH with offices on east & west coasts Group of 20 technical consultants and support staff Independent and brand neutral we do not sell equipment 1,200 systems audited and 800 air projects implemented Experience in all types of industries addressing both demand side and supply side issues 2

Compressor Electric Cost = Input HP x.746 x Hrs x Electric Rate / Motor Efficiency 100 psig, 4.0 cfm/input hp, 0.06 kwh, 8000 hours/yr 1 cfm = $100/Year in Electric Cost 4

Why Care About Air? 14 R s #1 Leaks #2 Pressure: Points of Use #3 Pressure: Source #4 Pressure: Fluctuations #5 Partly Loaded Units Compressors #6 Potentially Inappropriate Uses of Air #7 Pressure Drop #8 Dryer Sizing and Type #9 Condensate Drains #10 Preventative Maintenance #11 System Benchmarking #12 Usage Pattern Charting #13 Heat Recovery #14 Full Economic Evaluation #15 Retrocommissioning (O&M) 5

Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) 6 R#15 Retro-commissioning (O&M activities)

Plant Air 3 3 Areas of high turbulent driven back pressure 3 650 Gallon Receiver 3 3 Zeks 1100 scfm Mist Eliminator 3 Quincy QSI 750 150 HP Atlas Copco GA 55W 75 HP Atlas Copco GA 55W 75 HP 140 120 100 80 60 40 3 20 0 10/25/2007 2:00 10/24/2007 21:54 10/24/2007 23:57 Kilowatts 10/25/2007 4:03 10/25/2007 6:06 10/25/2007 8:09 10/25/2007 10:12 10/25/2007 12:15 10/25/2007 14:18 10/25/2007 16:21 10/25/2007 18 24 Bottling plant BEFORE 3 125 psig 3 3 3 3 ON ON ON/OFF Zeks 1000 scfm Non-Cycling D 105 psig Rental Tie In 50% Flow 80% Power 7

Bottling Plant 3 copper Short radius 90 copper T with opposing air flows creates a dead head. 8

Bottling plant AFTER o o o Eliminate crossing Tee s and Dead Head Replace copper pipe with properly sized low pressure loss extruded aluminum Add a large storage to allow 2 step controlled Atlas Copco to not short cycle. 80% Flow 85% Power 4 4 o o o 4 Lowered discharge pressure 20 psig Run (1) one single unit on weekends Nothing else on, run only Quincy 100% time during production Zeks 1000 scfm Non-Cycling Dryer Removal and Installation 3 Men 14 Hours 4 105 psig 3000 Gallon Receiver 4 4 4 4 105 psig 3 3 3 650 Gallon Receiver Quincy QSI 750 150 HP Atlas Copco GA 55W 75 HP Atlas Copco GA 55W 75 HP ON OFF OFF Rental Tie-in with aftercooler 9

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BOTTLING PLANT ECONOMICS PROJECT COSTS $99,068 REBATE $41,000 NET PROJECT COSTS $58,068 TOTAL SAVINGS $116,500 SIMPLE PAYBACK 6 months 11

Performance at Part Load With the exception of the new magnetic bearing driven centrifugal almost all air compressors are less power efficient at part load compared to full load. The type of compressor and type of local capacity controls determines the actual performance. The actual performance can be further enhanced with an effective central air management system. Well applied this can match optimum supply of air to the actual floor demand Many are not well applied 12

Compressor Use Profile Current System Actual Elec Demand Actual Air Flow Compressor Manufacturer/Model % of Full Actual % of Full Actual kw kw Flow scfm All Shifts: Operating at 110 psig discharge pressure for 8,760 hours Machine Shop Compressor Room Quincy 200-hp 27% 47.8 0% 0 Quincy 200-hp 83% 148 43% 418 Quincy 200-hp 93% 165 76% 691 Quincy 200-hp 92% 164 73% 644 Quincy 200-hp 92% 164 73% 644 Quincy 200-hp 13% 24 0% 0 Casting Compressor Room Quincy 300-hp 97% 253 90% 122.8 Quincy 300-hp 77% 206.6 23% 313 Quincy 300-hp 86% 220 43% 586 Quincy 200-hp 92% 162 73% 664 Quincy 150-hp 73% 112 10% 68 PreMelt Quincy 200-hp 91% 162 70% 636 TOTAL (Actual): Cost per year $883,332 1833.4 kw 5,892 scfm 13

Compressor Use Profile Modified System Actual Elec Demand Actual Air Flow Compressor Manufacturer/Model % of Full Actual % of Full Actual kw kw Flow scfm All Shifts: Operating at 110 psig discharge pressure for 8,760 hours Machine Shop Compressor Room Quincy 200-hp Quincy 200-hp Quincy 200-hp Quincy 200-hp Quincy 200-hp OFF Quincy 200-hp 99% 174.3 98% 891 Casting Compressor Room Quincy 300-hp 100% 266.34 100% 1,364 Quincy 300-hp 100% 266.34 100% 1,364 Quincy 300-hp 100% 266.34 100% 1,364 Quincy 200-hp 100% 176 100% 909 Quincy 150-hp OFF PreMelt Quincy 200-hp OFF TOTAL (Actual): Cost per year $553,742 1149.32 kw 5,892 scfm 14 Savings of $329,590 per year and 684.08 kw

Types of Venturi Vacuum Generators Single-Stage Multi-Stage Co-Axial 16 Courtesy of piab.com

Venturi Vacuum Generators Shut Shut off off air air supply supply not not the UPPLY vacuum the vacuum supply Solenoid or Manual Ball Valve M Compressed Air 17

Venturi Vacuum Generators Auto Shut Off Typical venturi vacuum generators on palletizer Auto shut off venturi generator 18

Venturi Vacuum Generators: Multi stage Co axial often more efficient than Single stage Inlet Pressure Single Stage Compressed Air Vacuum 45 8.6 12 50 9.4 14 55 10.2 16 60 10.9 18 65 11.6 22 70 12.4 25 80 13.8 27 100 16.8 26 Inlet Pressure Co axial Compressed Air Vacuum 45 4.2 26 50 4.6 26 55 4.9 26 60 5.3 26 65 5.7 26 70 6 24 80 6.7 24 100 8.2 22 19 Generate similar vacuum at lower pressure and lower flow

Larger Cups at Lower Vacuum Better holding forces while using less energy = less compressed air 20

Decentralize Vacuum System Use smaller point of use vacuum systems / Auto shut off Venturi vacuum generator with auto start/stop. On time =.72 minutes per hour Centralized $11,200 per yr / 112 cfm Decentralized AS&S $1,079 per yr / 1.079 cfm 21

Compressed Air Linear Actuators (Air Cylinders) Lowest Effective Pressure, Power and Return Stroke 23

High Pressure Low Pressure Possible New Technology 3/2 Valve X-Block High Pressure Low Pressure POWER STROKE 3/2 Valve X-Block RETURN STROKE 24

Two return air exhaust compressed air storage Two X-Block return stroke air controllers BEFORE 25 cylinders 7.82 cycles/min 105 psig 22 cfm ---------------------- AFTER Standard 2-way Control valve 7.82 cycles/min 95 psig 5.94 cfm 25

32 cfm 80 psig Venturi Amplifiers or Flow Inducers ¼ Tube 12 Inches Long 80 cfm - $3,200 year 80 cfm 26 cfm 80 psig ¼ Tube with Air Dispersion Nozzle 95 cfm - $2,600 year 95 cfm 10 cfm 80 psig ¼ Tube with Venturi Nozzle 250 cfm - $994 year 27 250 cfm

Typical Open Blow Application 1/4 Tube Open Blow uses 25 cfm: Add Fixed ¼ air amplifier: 9 cfm Energy Cost (Uncontrolled): $2,500 /yr Energy Cost w/ Nozzle: $900 /yr Energy Savings: $1,600 /yr Cost of Nozzle: $17 28

Steel Plant Rolling Mill Open Blow Energy Savings: $7,000 /yr Nozzle Cost: $110 29

Blow Off Air ¼ tube blows continuously to clear parts from press 32 cfm 30

CONTROL CABINET COOLING Do you actually need cabinet cooling? 32

Heat Pipe Cabinet Cooling Air-cooled will not cool below ambient; Water-cooled will 33

VORTEX TUBE REFRIGERATION CABINET COOLER Compressed air temperature Drop 60 to 90 o F Compressed Air 90 psig 70 o F Hot Air from Vortex Tube 230 o F Cabinet Air Exhaust Cold Air -10 o F 34

THERMOSTATIC AUTOMATIC SHUT OFF 110 Volt Normally Closed 2 way solenoid Air Supply Air Filter Cabinet Wall Ducting 8 long Thermostat Vortex tube cools quickly Unlimited starts & stops; just shut off / turn on Muffler 35

THERMOELECTRIC REFRIGERATION CABINET COOLERS Peltier Cooling Average cooling 10 30 o F Works in a totally sealed cabinet 36

Refrigerated Heat Pipe (Air or Water) Air Water 1,500 Btu/hr = 1.5 kw 1,500 Btu/hr =.035 kw.140 kw 6,000 Btu/hr = 2.0 kw 6,000 Btu/hr =.140 kw.035 kw 8,000 Btu/hr = 2.3 kw 8,000 Btu/hr =.140 kw.035 kw 12,000 Btu/hr = 3.5 kw 12,000 Btu/hr =.280 kw.105 kw Thermoelectric Max Nominal 400 Btu/hr Rating 100 Watts 70 Watts 800 Btu/hr Rating 200 Watts 150 Watts 1,500 Btu/hr Rating 400 Watts 280 Watts (20) 6,000 Btu/hr Refrigerated 40 kw $21,000/yr (20) 6,000 Btu/hr Heat Pipe 2.8 kw $ 1,475/yr 37

Pulse Jet Baghouse 39

Cleaning Pulse 40

Compressed Air Delivery and Supply May Create an Ineffective Pulse * Use proper line size to handle rate of flow without high pressure loss * Use of storage to supply air without pulling down feed to receiver/collector * Monitor inlet pressure and drop at pulse * Monitor flow 41

Typical Compressed Air Use One, 10 row Dust Collector Valve Size Standard Pulse with Demand Control Continuous 356 pulse/hour $ / Year Avg. scfm $ / Year Avg. scfm 3/4 $1,007 10.7 $3,205 32.05 1 1/8 $2,040 20.4 $6,109 61.09 1 1/2 $3,550 35.5 $10,610 106.61 2 $4,890 48.9 $14,663 146.63 42

Optimizing Air operated Double Diaphragm Pumps Control Pressure Control Cycles Automatic Shut-off Controls Covert to Electric Install Electronic Stroke Optimizers 44

Air-operated Diaphragm Pump Compared to Electric 2 Diaphragm Pump / Water/ 40 foot head 75 gallons per minute 75 psig inlet pressure 70 cfm $7,000 per year Electric Pump 3 Horse Power $780 per year 45

Electronic Optimized Stroke Control, Pneumatic operated or 24V AirVantage Pneumatic Potential Compressed Air Savings $3,000 to $6,000 / year Cost $1,000 to $1,200 MizAir 24v Electric Drive 46

Electronic Stroke Optimizer At the same input pressure, the compressed air usage fell 36% to 50% The stroke rate falls to optimum rate The product capacity per stroke increased Product flow per unit of energy increased from 50 to 100% efficiency Run quieter low exhaust 47

14 R s #1 Leaks #2 Pressure: Points of Use #3 Pressure: Source #4 Pressure: Fluctuations #5 Partly Loaded Units 5 15% 0 2% 0 2% 0 2% 0 10% #6 Inappropriate Uses of Air #7 Pressure Drop #8 Dryer Sizing and Type #9 Condensate Drains #10 Preventative Maintenance 5 10% 0 2% 0 2% 0 1% #11 System Benchmarking #12 Usage Pattern Charting #13 Heat Recovery #14 Full Economic Evaluation #15 Retrocommissioning (O&M) 0 5% 49

Did You Know? 30% of all compressor controls or control systems are not operating properly 40% of all air system dryers are installed improperly, plugged, bypassed, or otherwise not performing their intended purpose 50% of all air systems are not piped correctly 60% of all plants could reduce their air demand by 1/4 if they eliminated the air use or switched to an alternative energy source Amazingly, 30% of all brand new or reconstructed air systems are engineered incorrectly 50

Thank you for this opportunity to present Come visit our hands-on exhibit (740) 862 4112 airpowerusainc.com Hank van Ormer John Skelton Air Power USA Inc 51