Strategies to Reduce Compressed Air

Costs on the Demand Side

Nipsco Symposium

Merrillville, Indiana

October 8, 2014

The Best Opportunities to Improve Efficiency

and Reduce Costs of Your Compressed

Air System on the Demand Side

Compressed Air System Efficiency

3

Compressed Air is NOT Free

4

Compressed Air vs. Electric

5

Energy Cost Calculation

6

Artificial Demand

7

Operating Cost Reductions

8

The Basic Rules

Bottling Plant Before Compressor

Room Piping and Design

9

Bottling Plant After New Design and

Materials

10

After with 4” Aluminum Alloy

Reusable Piping

11

12

Bottling Plant Economics

13

Types of Venturi Vacuum Generators

Venturi Vacuum Generators

14

Venturi Vacuum Generators

15

Venturi Vacuum Generators

16

Venturi Vacuum Generators

17

Multi-stage Co-axial are more efficient than Single-stage

Air Cylinder / Dual Pressure

Regulators

18

19

Air Cylinders

Blow-off Air

20

21

Low Pressure Blower Generated

Blow-off Air

Use Low Pressure Air Whenever Possible!

22

Blow-off Air

23

Shut off blow-off air when not needed

Blow-off Air

24

Blow-off Air

Replace blow-off air with Mechanical

25

Blow-off Air

26

Control Cabinet Cooling

Do you actually

need cabinet

cooling?

Heat Pipe Cabinet Cooling

27

Vortex Tube Refrigeration

Cabinet Cooler

28

Thermostatic Automatic Shut-Off

29

Thermoelectric Refrigeration Cabinet Coolers –

Peltier Cooling

30

31

Cabinet Cooling

Optimizing Air Operated Double

Diaphragm Pumps

32

AODD Comparison

33

34

Air Operated Double Diaphragm

Pumps

35

Air Vibrators

Air Motors

36

Air & Electric Driven Motor Hoists

37

5,000 Lb. Class Hoist

Air Motor - Driven Mixers

38

Compressed Air Leaks

39

40

Compressed air leaks -- 60 leaks at 280 cfm

Estimated cost to repair $6,000

Recoverable energy savings $28,000/year

Compressed Air Leak Examples

41

Compressed Air Leak Example

THANK YOU for this Opportunity to Present

Hank van Ormer

Air Power USA, Inc.

740.862.4112

hank@airpowerusainc.com