Industrial Utility Efficiency    

System Assessments

Blower & Vacuum Best Practices interviewed Republic Manufacturing VP of Sales & Marketing, Rich Leong. Our line of regenerative blowers, also known as side channel blowers, are for vacuum or compressed air applications in both horizontal and vertical mounted positions. Airflow capabilities range from 50 to 776 CFM, vacuum capabilities from 47" to 236" of water (1.7 psi to 8.53 psi) and pressure capabilities up from 47" to 307" of water (1.7 psi to 11.09). TEFC electric motors are cUL and CE certified and come in single and three-phase, dual frequency and multi-voltage versions for worldwide applications. Horsepower ranges from 1/2 to 40 HP (from 0.4 to 30kW).

Blow-off Air

A metal producer, in the Midwest, spends an estimated $2.4 million annually on electricity to operate their compressed air system.  The current average electric rate, at this plant, is 5.5 cents per kWh, and the compressed air system operates 8,760 hours per year. This system assessment recommended a group of “near-term” compressed air demand reduction projects and then a group of separate “longer-term” projects focused on optimizing the air compressors, the controls and the heated desiccant compressed air dryers. The near term demand-reduction projects...

Vacuum Controls

Meat packaging plants have long used vacuum pumps as a way to remove air and reduce the amount of oxygen in their products’ plastic packaging. Vacuum packaging extends the meat’s shelf life while protecting its flavor and exposure to outside elements, such as freezer burn and bacteria.

Vacuum Generation

Air-driven Venturi vacuum generators have long been a viable option for fast-response, localized, vacuum-powered systems. Through the last decade, they were considered convenient and flexible solutions with quick response time. However, they were not regarded as energy efficient, probably due to their use of compressed air. Extensive product development with this equipment — particularly the crucial system accessories — often makes the selection of the most energy-efficient items difficult for many localized operations.

Pressure/Vacuum

Machine builders aiming to improve the energy efficiency of their machines tend to focus on using energy media other than pneumatics (typically electro-mechanical or hydraulic) since pneumatics, as traditionally applied, is viewed by some as inefficient due to factors like leakage and over-pressurization (i.e.: supplying a higher pressure in an actuator to accomplish a task which is endemic in practice). But they shouldn't, with its low cost of ownership, pneumatics when properly used remains a viable and many times preferable energy source for a given application.

Conveying

In open end pipe line suspension flow, or dilute phase pneumatic conveying, proper particle velocity is critical to continuing productivity and product quality. Until recently, measurement of actual particle velocity within the pipe has not been practical outside the laboratory. The plant operating personnel depend on a much less accurate metric - estimating the conveying air velocity in the pipe and relating that to particle velocity.

Blower Controls

The capacity and pressure requirements of blowers in a Water Resource Recovery Facility (WRRF) are determined by the aeration system. When systems are manually controlled blowers often operate at constant flow and pressure day in, day out. When the aeration system is automatically controlled to maintain a set dissolved oxygen (DO), however, the blower’s flow and system pressure vary constantly. Understanding these variations will help designers and suppliers optimize blower performance.
This article will focus on optimizing the demand-side so the centralized “supply-side” (the vacuum pumps and controls) can then run at a lower energy and maintenance cost. First, I will start with a simplified model of a vacuum pump system demands. See Figure 1 for a one-pump/one-demand simplified system. See Figures 2-6 for some typical controlled and uncontrolled demands. The symbol with the three lines is an orifice, a hole essentially. I am defining three types of system demands adding up to the total demand on the vacuum pump.
Electric utility incentive programs encourage industrial and manufacturing companies to reduce power consumption by paying part of the cost to upgrade to more efficient equipment. It’s a great concept, but many customers only go after low-hanging fruit, such as upgrades for lighting or air compressors, and go no further.
Blower & Vacuum Best Practices interviewed Republic Manufacturing VP of Sales & Marketing, Rich Leong. Our line of regenerative blowers, also known as side channel blowers, are for vacuum or compressed air applications in both horizontal and vertical mounted positions. Airflow capabilities range from 50 to 776 CFM, vacuum capabilities from 47" to 236" of water (1.7 psi to 8.53 psi) and pressure capabilities up from 47" to 307" of water (1.7 psi to 11.09). TEFC electric motors are cUL and CE certified and come in single and three-phase, dual frequency and multi-voltage versions for worldwide applications. Horsepower ranges from 1/2 to 40 HP (from 0.4 to 30kW).
A metal producer, in the Midwest, spends an estimated $2.4 million annually on electricity to operate their compressed air system.  The current average electric rate, at this plant, is 5.5 cents per kWh, and the compressed air system operates 8,760 hours per year. This system assessment recommended a group of “near-term” compressed air demand reduction projects and then a group of separate “longer-term” projects focused on optimizing the air compressors, the controls and the heated desiccant compressed air dryers. The near term demand-reduction projects...
Energy for the entire Ernst Sutter AG company – and consequently the Suttero Bazenheid premises as well – is generated via hydropower. In addition, around 75% of the energy from refrigeration is also used to generate hot water. When creating vacuum for packaging, Suttero Bazenheid relies on a centralized vacuum system from Busch. This is significantly more energy-efficient in operation than decentralized vacuum supplies on individual packaging machines. As a result, Ernst Sutter AG has created a production plant that corresponds to the latest standards, both from a technical and ecological perspective. 
The market health is moderate. 2017 was a better year than 2016, which saw a slight decline. With that said, 2017 will be a good year for us. One major trend impacting the industrial vacuum market is industry consolidation. Busch employees and clients benefit against this dynamic market environment, from the strength and stability of our family-owned business- a business with over 3,000 employees in over 60 subsidiaries worldwide. The average tenure, for a subsidiary General Manager, is twelve years. This allows us to stay focused on managing for the long term benefit of customers and employees.
Most-Open-Valve (MOV) can be a cost-effective way to optimize aeration energy. It can also be a confusing and troublesome addition to a process automation project. In my experience MOV is the least understood aspect of aeration control. This article will shed light on MOV, the process and energy impacts and why it’s worth the trouble.
Meat packaging plants have long used vacuum pumps as a way to remove air and reduce the amount of oxygen in their products’ plastic packaging. Vacuum packaging extends the meat’s shelf life while protecting its flavor and exposure to outside elements, such as freezer burn and bacteria.
At Scholle IPN, Valley Packline’s engineering experience and JetAir’s drying expertise came together to deliver an automated, energy efficient solution. Ultimately, the new system eliminated 120 man-hours each week dedicated entirely to erecting and washing. The new system can be manned by just one employee as it pulls bins directly off delivery trucks, re-erects, washes, and dries them, and feeds them into the facility for refilling. Throughput at Scholle was improved by the system, while energy costs were kept to a minimum.
This article reviews two common pneumatic conveying system types and the importance for each operating plant to know their design and operating parameters particularly conveying air flow velocity and particle velocity profile.