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2 Advanced Trends in Compressed Air Best Practices March 6, 2013 Rod Smith, Editor, Compressed Air Best Practices Magazine Mary Bentsen, Education and Training Coordinator SAIC, an Ameren Illinois ActOnEnergy Partner

3 Practical Items If you can't hear me, please type a message in the Chat window located on the righthand side of your screen. Please type any questions you have during the presentation into the Chat window located on the right-side of your computer screen.

4 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?

5 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 We Thank our Board Members for providing this information!

6 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 We Need Your Help! Please sign up for a free print Subscription.

7 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

8 7/20/ :08 7/20/ :14 7/20/ :20 7/20/ :27 7/20/ :33 7/20/ :39 7/20/ :45 7/20/ :51 7/20/ :58 7/20/ :04 7/20/ :10 7/20/ :16 7/20/ :22 7/20/ :29 7/20/ :35 7/20/ :41 7/20/ :47 7/20/ :53 7/20/ :00 7/20/ :06 7/20/ :12 7/20/ :18 7/20/ :24 7/20/ :31 7/20/ :37 7/20/ :43 7/20/ :49 7/20/ :55 7/20/ :02 7/20/ :08 7/20/ :14 7/20/ :20 7/20/ :26 7/20/ :33 7/20/ :39 7/20/ :45 Kilowatts Pressure 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 Unit 1 Unit 2 Unit 4 Unit 5 Unit 2 Discharge Press Unit 4 Discharge Press System Press

9 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

10 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 Flow changes but kw does not change proportionally Reducing Demand Does NOT Save Energy WITHOUT the appropriate Compressor Controls Flow MEC_SCFM Total Kw kw / Energy 0

11 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

12 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

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

14 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, pointof-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.

15 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

16 Phase 2 Advanced Trend The Energy Costs of Air Quality Specifications Energy Costs Associated with Pressure Dewpoint Specifications The ISO 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

17 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.

18 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

19 Phase 2 Advanced Trend Optimizing Pneumatics in OEM Equipment 3-position valve does not use air when machine is idle Stock Image: Unitizing & Palletizing Machine 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

20 Phase 2 Advanced Trend Purchasing Specs to include Energy Costs in OEM Production Equipment * kw * Pressure (psig) * Idle Flow (scfm) * Production Flow (scfm) Unitizing Machine After 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

21 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

22 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 Please Recommend our FREE Print Publication to your Colleagues. - Rod Smith, Editor tel: rod@airbestpractices.com

23 The Ameren Illinois ActOnEnergy Business Program Over $30 million in energy-efficient cash incentives

24 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

25 Compressed Air - Retro Commissioning Program Typical Measures Leaks Plant Pressure Reduction Controls Tune-Up Zero-Loss Drains Inappropriate Uses 25

26 Compressed Air - Custom Program Typical Measures Air Management System Flow Controller Sequencer Air Receiver Tank Variable Speed Drive Compressor Base-load/Trim Air Dryer Upgrades 26

27 Compressed Air - Leak Survey & Repair Program Typical Measures Leak Detection & Leak Repair 27

28 Compressed Air - Feasibility Study Program Typical Measures Air Management System Flow Controller Sequencer Air Receiver Tank Variable Speed Drive Compressor Baseload/Trim Air Dryer Upgrade 28

29 Ameren Illinois ActOnEnergy Energy Advisors

30 Find a Contractor Click here to find a Contractor who is an ActOnEnergy Program Ally.

31 Resources Website: ActOnEnergy.com/Business Phone: Fax:

32 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?

33 Questions? v

34 2013 ActOnEnergy Business Symposium May 21: East Peoria Embassy Suites May 22: Collinsville Gateway Center

35 VFD Bonus