Compressed Air Systems. Wasting Energy Since The Start Of The Industrial Revolution!

Transcription

1 Compressed Air Systems. Wasting Energy Since The Start Of The Industrial Revolution! Jeff Scott, CEM, CMVP Key Accounts & Outreach Manager ENWIN Utilities Ltd., Windsor, Ontario, Canada 2018 Energy Summit (May 30-31, 2018) Disclaimer: All Slides created by ENWIN Utilities Ltd.

2 About the Speaker Responsible for key accounts and industrial customer outreach in ENWIN Utilities (Windsor) territory Is a Certified Energy Manager (CEM) and Certified Measurement & Verification Professional (CMVP) Over 20 years experience in the compressed air & gas industry

3 Why Customers Should Care About Compressed Air? Utility costs rising and they want to reduce costs Need to replace old compressor or expand existing system Need to fix air system and don t know where to start Production is suffering due to downtime, or inadequate pressure. Compressed air can secretly wreak havoc on production in many ways.

4 Why Energy Conservation Staff Care About Compressed Air? Can represent one of the largest energy consumers in some industrial facilities Can represent one of your greatest energy reduction opportunities Most compressed air systems are misunderstood and poorly utilized Customers will often consider them a priority project once the costs are understood

5 A Word of Warning

6 Compressed air is. NOT FREE! Often referred to as the 4 th utility One of the most inefficient forms of energy in an industrial facility One of the most poorly utilized and misunderstood systems Often out of sight and out of mind

7 A Lifetime of Compressed Air Costs 1 Shift 2 Shifts 3 Shifts 2,800 Hours 5,600 Hours 8,400 Hours 50 HP $10, $20, $31, (37 KW) 104,440 KWh's 208,880 KWh's 313,320 KWh's 100 HP $20, $41, $62, (75 KW) 208,880 KWh's 417,760 KWh's 626,640 KWh's 500 HP $104, $208, $313, (373 KW) 1,044,400 KWh's 2,088,800 KWh's 3,133,200 KWh's 1,000 HP $208, $417, $626, (746 KW) 2,088,800 KWh's 4,177,600 KWh's 6,266,400 KWh's 2,500 HP $522, $1,044, $1,566, (1,865 KW) 5,222,000 KWh's 10,444,000 KWh's 15,666,000 KWh's Assuming 7 days/week, 50 weeks/year, and $.10/KWh

8 Where Do You Start With Compressed Air? Two distinct systems: o Supply Side which includes compressors, storage, air quality equipment, and controls o Demand Side which includes distribution system, secondary storage, and end-use equipment 8

9 Solutions - Supply Side Right sizing Controls Sequencing multiple compressors

10 Solutions - Supply Side Increased system storage Reducing system pressure Preventative maintenance Heat recovery

11 Solutions - Supply Side Other Compressor Room Items: Refrigerated Air Dryers Thermal mass, cycling, or VFD Regenerative Air Dryers Dewpoint dependent switching Assorted purge methods Heated purge Blower purge Vacuum purge Low pressure drop filters Maintenance Zero air loss drain valves

12 Solutions Distribution Systems A closed loop system is recommended Large consistent pipe diameter Avoid too many elbows, tees, etc. Keep it simple! Drops should come off the top of the main header to prevent any condensate from entering the process. Account for any critical application and high-volume/intermittent applications by installing satellite air receivers and metered recovery

13 Solutions Pressure Reduction Reducing pressure also reduces the amount of energy lost by leaks Regulate the system and points of use Lockable? Pressure is often raised to appease a specific process or machine Booster?

14 Solutions Inappropriate End Uses Address points of use for volume, pressure, and quality Challenge point of use requirements and appropriateness or inappropriateness of applications Investigate and address high volume, intermittent applications (metered recovery?)

15 Solutions Inappropriate End Uses

16 Solutions Leak Repairs Typical system has 15 25% air leakage Normally a simple payback of less than 6 months Not caring about leaks could lead to increasing compressor system capacity

17 Solutions Leak Repairs Leak management MUST be an ongoing process Leak tag and awareness program Try a weekend leak audit Duct tape is NOT an acceptable solution

18 Action Items Basic block diagram Supply and Demand sides Baseline and calculate energy use and costs Implement control strategy Baseline, determine leak load and recalculate Identify and fix leaks Reduce pressure

19 Action Items Correct inappropriate uses Check preventive maintenance items and other opportunities to reduce costs and improve performance Review distribution system and identify high volume demands Dedicated/metered storage Re-measure, and optimize controls Implement continuous improvement program

20 Available Resources Compressed Air Challenge Training sessions (Fundamentals & Advanced) Eligible for IESO Training incentive program Online resources Compressed Air & Gas Institute (CAGI) Compressed Air Best Practices E-Magazine Your Compressed Air Service Provider Your Electricity Service Provider! WE WANT TO HELP!

21 My Contact Information Jeff Scott, CEM, CMVP Key Accounts & Outreach Manager Industrial ENWIN Utilities Ltd. Tel: (519) Ext:

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23 Questions?