Industrial Utility Efficiency    

Technology

Turndown designates the operating range of an aeration blower or a blower system – and it can often be the most important factor in determining the ability of a system to match process demand. It is also critical to the system’s energy optimization. Unfortunately, in designing blower systems and controls turndown is not always given the attention that its importance merits. Here’s a look at the critical nature of turndown in wastewater treatment plants and recommendations for ensuring adequate turndown when utilizing Positive Displacement (PD) and centrifugal blowers.

Aeration Blowers

Efficiency compares the inputs used by a system to the outputs produced. It is a commonly used concept, but one which is prone to a great deal of misuse in many industries. This article provides insight into the parameter known as “efficiency,” how it’s calculated, and importantly, it’s uses and limitations in predicting blower energy consumption and comparing alternate system designs.

Industrial Blowers

Blower systems designed to deliver continuous airflow at pressures of 50 psig or below are critical to the operation of many processes including wastewater treatment, pneumatic conveying, fluid catalytic cracking, and fermentation to name a few. Many circumstances could arise that require an operator to require a rental blower for a period.

Rough Vac

Many heat-treating applications put difficult demands on vacuum pumps in general and oil-sealed pumps, in particular. Byproducts from the heat-treating process can contaminate the vacuum pump oil and create higher vapor pressures that cause deteriorated vacuum levels in the heat-treating chamber, or buildup and blockages in the pump mechanism.

Medium/High Vac

The European XFEL is a new international research facility, where 12 European countries participate. The non-profit society European XFEL GmbH is responsible for the construction and operation of the X-ray laser. DESY (Deutsches Elektronen-Synchrotron), one of the leading centers for the investigation of the structure of matter worldwide and a long-term partner of Pfeiffer Vacuum, is the main share- holder.

Measurement

Every municipality and utility is facing the reality of rising energy costs. In 2010, the Town of Billerica, MA, which is located 22 miles northwest of Boston with a population of just under 40,000 residents, engaged Process Energy Services and Woodard & Curran to conduct an energy evaluation of the Town’s Wastewater Treatment Facility (WWTF) and pump station systems sponsored by National Grid. The objective of the evaluation was to provide an overview of each facility system to determine how electrical energy and natural gas were being used at the facility and to identify and develop potential costsaving projects.

Purification

Contamination such as humidity, oxygen or microbiological ingress can impact drug stability throughout the product life cycle. To prevent the risks of stability failure of highly moisture sensitive drugs (e.g. dry powder for inhalation), or the risk of biological ingress of parenteral drugs, highly sensitive integrity tests are required. Most test methods are very challenging in regards to time, effort, complexity or the limitation of sensitivity and detection range.

Vac Generation

Using suction cups and air-driven vacuum pumps is a preferable gripping and handling method of corrugated cardboard materials and boxes in carton-machines like case/carton erectors and rotary cartoners. Robot based applications, like palletizing and de-palletizing, are other examples where the best practice technology for gripping and handling is by suction cups and air-driven vacuum pumps.  
Productivity is more reliable when equipment can be monitored to detect incipient failures and take corrective action before the plant goes down. But many devices, such as analog control valves, pneumatic valve terminals and field sensors, often do not offer diagnostic feedback, or it is not being used. This white paper describes how this problem is being addressed, and includes an example of pneumatic valve terminals that can monitor, among other things, open load or coil currents at the specific valve and pressure inside the valve terminal.
With the continuing increases in energy costs and the requirements of Biological Nutrient Removal (BNR), the design of the aeration system has become one of the most important aspects of the design of the activated sludge process.
It’s one thing to move materials during the production process, but when it’s a finished product on the packaging line, choosing the right material handling system is essential. Getting it wrong results in squandered production time when product loss occurs, and wasted raw materials.
Nutriom sets the bar high when it comes to producing its premium quality natural powdered egg products Ova Easy® and Egg Crystals®, that are sold at outdoor retailers such as REI, and online merchants such as Amazon.com; so, when the screw conveyor in their FSIS USDA facility required regular unexpected attention, Leonardo Etcheto, Plant Manager at the Lacey, WA facility knew it was time to look for a better solution.
This food & beverage plant is a large (500,000 sq ft) meat processing plant with twenty packaging lines and nine palletizers. The compressed air system is supplied from three separate rooms with seven individual lubricant-cooled, single and two-stage rotary screw compressors. The plant has four blower purge desiccant dryers designed to deliver a - 40°F pressure dewpoint.
This was a complete supply and demand-side system assessment. The supply-side audit involved shutting off old air compressors and purchasing newer more efficient air compressors and dryers. The demand-side audit involved finding ways to improve the piping and reduce compressed air consumption. Annual plant electric costs for compressed air production, as operating today, are $3,050,625 per year. If the electric costs of $27,811 associated with operating ancillary equipment such as dryers are included the total electric costs for operating the air system are $3,078,436 per year.
With sustainability and energy-efficiency targets tougher than ever, magnetic bearings are drawing the attention of engineers in many industries, offering a whole range of advantages from increased performance to extended lifespan.
Recently the capacity of the Las Palmas, California, waste water treatment operations were expanded by combining two plants and making one centralized filtration center. The new center expanded the flow capacity from 162,000 Gallons per Day (GPD) combined to 288,000 GPD when the manually controlled reclaimed water operations were updated to a state-of-the-art automated system. Reclaimed water from the plant irrigates local community green spaces. The new automated system ensures lower labor costs, consistent quality, and peak efficiency in the process of reclaiming waste water for irrigation.
In the absence of official third party specifications on energy efficiency, it is difficult to evaluate and compare blower technologies fairly and effectively. The lack of readily available evaluation tools leads to misinformation and unfair comparisons between technologies. Further, the performance verification process is difficult to prove.
The plant air system consists of eight, single-stage, lubricated, Sullair rotary screw compressors. All units are in good working order.  Units 2, 3, 4 and 7 are water-cooled and units 6, 8, 9, 10 and 11 are air-cooled. The main plant air system has two primary compressed air dryers, a Thompson Gordon model TG 2000 refrigerated dryer, and a Sullair model SAR 1350 heatless desiccant dryer.  Both units are working according to their design. The TG 2000 uses approximately 11.2 kW and is a non-cycling type unit, and the SAR 1350 uses approximately 200 cfm of purge air to regenerate the wet tower.