COMPRESSED AIR SYSTEM COSTS Best Opportunities to Improve Efficiency and Reduce Electrical Consumption of your Compressed Air System

Transcription

1 COMPRESSED AIR SYSTEM COSTS Best Opportunities to Improve Efficiency and Reduce Electrical Consumption of your Compressed Air System Hank van Ormer Air Power USA airpowerusainc.com 1

2

3 8 Horsepower Electrical Energy = 1 Horsepower Work with Compressed Air 3

4 Energy Cost = Input HP x.746 x Hrs x Electric Rate / Motor Efficiency 1 cfm = $100/Year Power Cost (100 psig, 4.0 cfm/input hp,.06kwh, 8000 hours/yr) Extra Pressure Means Extra Power 1 PSIG = 2 /5% (or x.004) Power 1 PSIG of 100 HP Compressor = $159/Year PC (.06 kwh, 8000 HR,.9ME) 4

5 Artificial demand (running at higher than necessary pressure) EXTRA PRESSURE EXTRA DEMAND With no increase in productivity or quality a waste 5

6 Artificial Demand Increased flow due to higher pressure 1/8 ORIFICE TEST 30 PSIG 60 PSIG 90 PSIG 10.1 CFM $587 per year 16.9 CFM $983 per year 23.7 CFM $1,379 per year 6

7 Operating costs reductions are worth more than sales and productivity dollars Cost reduction vs. productivity / profitability $100,000 in costs reduction = $2,000,000 sales at 5% net profit 7

8 Rules Number 1 & Turn off when not needed 2 - Operate at the lowest effective pressure 8

9 Aluminum and Stainless Steel Piping with Reusable Fittings Easy and Flexible to Correct Piping Issue 9

10 10/24/ :54 10/24/ :57 10/25/2007 2:00 10/25/2007 4:03 10/25/2007 6:06 10/25/2007 8:09 10/25/ :12 10/25/ :15 10/25/ :18 10/25/ :21 10/25/ :24 10/25/ :27 10/25/ :30 Kilowatts Bottling plant BEFORE psig 125 psig % Flow 80% Power 10 ON ON ON/OFF

11 Bottling Plant 3 copper Short radius 90 copper T with opposing air flows creates a dead head. 11

12 Bottling plant AFTER 80% Flow 85% Power 4 4 Removal and Installation 3 Men 14 Hours psig psig ON OFF OFF 12

13 BOTTLING PLANT ECONOMICS PROJECT COSTS $48,493 ELECTRICAL SAVINGS $58,068 REBATE $41,000 TOTAL SAVINGS W/ REBATE $99,068 SIMPLE ROI 5.7 MONTHS 13

14 Venturi Vacuum Generators Compressed Air Evacuated Air Exhaust Air 14

15 Types of Venturi Vacuum Generators Single-Stage Multi-Stage Co-Axial 15 Courtesy of piab.com

16 Venturi Vacuum Generators Shut Shut off off air air supply supply not not the vacuum the vacuum supply 16

17 Venturi Vacuum Generators Auto Shut Off Typical venturi vacuum generators on palletizer Auto shut off venturi generator 17

18 Venturi Vacuum Generators: Multi-stage Co-axial often more efficient than Single-stage Inlet Pressure Single-Stage Compressed Air Vacuum Inlet Pressure Co-axial Compressed Air Vacuum Generate similar vacuum at lower pressure and lower flow

19 Larger Cups at Lower Vacuum Better holding forces while using less energy = less compressed air 19

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 / cfm 20

21 Lifting with an NCT (non-contact transfer unit) 21

22 Examples of objects which the NCT can handle 22

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

24 8 cuft $ per yr 16 cuft $ per yr 24 cuft $1, per yr High Pressure = More Compressed Air Are you operating at lowest effective pressure? 24

25 Dual Pressure Regulators 80 psig 90 psig 90 psig 30 psig 25

26 Linear Air Cylinders Too high of pressure with improper tube-tocylinder size and solenoid selection. Use storage to offset regulator delay do not raise inlet pressure 26

27 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 27

28 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 28

29 Electric Linear Actuators ELECTRIC MOTOR DRIVEN LINEAR ACTUATOR Qty 10, 1-7/8 x 6 at 60 psig replaced, 7,000 hours / Savings $3,650 year 29

30 Blow Off Air 30

31 Blow Off Air for Cleaning, Cooling, Drying Low pressure blower air Lower cost to produce 31 Low Thrust / High Volume

32 LOW PRESSURE BLOWER GENERATED BLOW OFF AIR Electrical Energy Cost to produce psig = $43,000 Electrical Energy Cost to produce psig = $26,000 Electrical Energy Cost to produce psig = $18,000 Electrical Energy Cost to produce psig = $ 8,000 Compressed Air Knife 12 3 cfm Per Inch $2452 / year Blower Air Knife $350 / year 32

33 Basic Compressed Air Blowing Technology Thrust (psig) to knock it loose or break inertia Volume (cfm) to move the material away Cooling Temperature may be least significant Volume (cfm) creates the necessary mass to absorb the heat Lack of performance is often not enough air volume 33

34 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 250 cfm 34 34

35 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 35

36 Steel Plant Rolling Mill Open Blow Energy Savings: $7,000 /yr Nozzle Cost: $110 36

37 Venturi Amplifiers or Flow Inducers Adjustable Thrust Work with your supplier or consultant! Venturi amplified compressed air 37 Conventional

38 Blow Off Air ¼ tube blows continuously to clear parts from press 32 cfm 38

39 Shut Off Blow Air When Not Needed 39

40 Venturi Amplifiers or Flow Inducers Lower Operating Cost Improve Productivity Improve Quality Lower noise level OSHA safe 40

41 CONTROL CABINET COOLING Do you actually need cabinet cooling? 41

42 Heat Pipe Cabinet Cooling Air Cooled Will Not Cool Below Ambient; Water Cooled will 42

43 Air-to-air cooling Air-to-water cooling 43

44 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 44

45 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 45

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

47 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

48 Dust Collectors Offer Particularly Great Opportunities for Compressed Air Savings 48

49 49

50 outlet 50

51 51

52 ΔP 52

53 53

54 Sequence Controllers Require Proper Line Size Available Air Rate of Flow Problem: Flow / Rate of Flow 54

55 Typical Sizing 3.5 scf per pulse in 1/2 second - 6 valve Total Flow of 21 scf Sequential Every 7 seconds Rate of Flow 420 scfm 2 feed at 1 psid / 100 ft All Open Together Rate of Flow 2,520 scfm 2 feed at 45 psid / 100 ft 6 feed <1 psid / 100 ft 55

56 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, $3, /8 $2, $6, /2 $3, $10, $4, $14,

57 Optimizing Air Operated Double Diaphragm Pumps * Control Pressure * Control Cycles * Automatic Shut Off Controls * Convert to Electric * Install electronic stroke optimizers 57

58 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 58

59 MizAir cutaway To Pump Compressed Air In 59

60 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 60

61 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 61

62 Miscellaneous Common Sense Option Air Vibrators $700/year Air vibrator Electric Vibrators $109/year New electric vibrator 62

63 Vibrator Parts Sorters Compressed Air $800/yr Pneumatic vibrator driving the base and the parts feeder bowl Electric $100/yr Electric vibratory parts sorter 63

64 New Central Air System 660-hp & HOC Dryer Units 3 & 4 ON Units 1 & 2 OFF 660-hp & HOC Dryer 660-hp & HOC Dryer 660-hp & HOC Dryer 64

65 Other Less Efficient Systems Operation 65

66 Co-Generation Average kw per unit 34.6 kw (65% flow / 80% power) 66

67 Orange Juice Plant When completed, four additional areas of local air were shut off and the process put on a central system Processing West -- $9.669/year Pallet repair -- $3,208/year South campus -- $5,555/year Total savings = $55,384/year More efficient compressed air supply SEEMS SIMPLE?? RUN YOUR MOST ENERGY EFFICIENT UNITS 67

68 Automatic Drain Traps 68

69 Timer Drains Annual Electrical Cost = $310/yr Open Drain = $10,000/year 69

70 70

71 Heat Recovery 71

72 Cooling Air Ducting Not Working Correctly Room 95ºF Inlet air 104ºF Air/Oil 210ºF at FL at 100 psig Air/Oil 215ºF at FL at 120 psig Cooling Air Ducting Working Correctly 72

73 90% of total energy to produce air may be recoverable 73

74 74 74

75 Compressed Air Leaks 75

76 Compressed air leaks leaks at 280 cfm Estimated cost to repair $6,000 Recoverable energy savings $28,000/year 76

77 Leak #4 Note: Pressure gauge is reading about 85 psig entering the leaking hose. We elected to set the UE3000 sensing level at an estimated 75 psig. The instrument measured 2.9 scfm, the CDI meter reads 3.1 scfm! Figure 7. June List of Tagged Air Leaks Record Number Group Name Location Name Type of Gas Pressure at Leak (est.) db Reading Problem Description Size of Leak CFM 1 Pipe mill Labeling Air QDC Male&FM west grinder Pipe mill Labeling Air Threads on 1/4 elbow to reg (1) Pipe mill Labeling Air QDC Male&FM (1) 1.0 Trim 4 Pipe mill bevel N Air /2" Hose Blister west side grinder Pipe mill Trim bevel N Air Threads at ball valve (2)

78 Identify / Tag / Repair Leaks Total CFM of Leaks Tagged 5288 CFM (1250 HP) 31% of Total Compressed Air 78

79 Air & Electric Driven Motor Hoists 5,000 Lb Class Hoist Electric: 5,600 lbs base drum pull Average price $3,000 each 1.5 kw x $.06/kWh x 1-hr = $.09/hr Electrical Cost Pneumatic: 28-hp, 23.2 kw 5,000 lbs base drum pull Average price $3,500 each 23.2 kw x $.06/kWh x 1-hr = $1.39/hr Air Cost 79

80 Air Motor Electric: 3-hp air motor = $10,512/year 2 kw electric motor = $1,051 year 80

81 Sandblast Nozzles & Suction Entry Pressure vs Air Flow 81

82 Nozzle Diameter Air Flow Cfm Through Pressure Blast Nozzle Blast Pressure / / / / / / / / Nozzle Size Air Jet Size Air Flow Cfm Through Suction Blast Gun Blast Pressure /4 1/ /16 5/ /8 3/ /16 7/

83 Thank You IMTS and Hydraulics & Pneumatics for this opportunity to present. Hank van Ormer Air Power USA, Inc airpowerusainc.com 83