EMERGING TECHNOLOGIES AVAILABLE TO REDUCE COMPRESSED AIR DEMAND Double Acting Air Cylinder Double Acting Air Cylinder Air Operated Diaphragm Pumps Air Operated Diaphragm Pumps Optimizing Blow Off Air Optimizing Blow Off Air Cabinet Cooling Cabinet Cooling

8 Horse Power Electrical Energy = 1 Horse Power Work with Compressed Air

COMPRESSED AIR CYLINDER IMPROVEMENTS IN OPERATING EFFICIENCY

EXTRA PRESSURE AT THE COMPRESSOR = EXTRA ENERGY CYLINDER EXTRA PRESSURE = EXTRA AIR CFM $465 / YEAR $931 / YEAR $2793 / YEAR 30 PSIG 60 PSIG 90 PSIG

FILTERREGULATOR LUBE CYLINDER STORAGE VESSEL SOLENOID

3/2 Valve High Pressure Low Pressure POWER STROKE 3/2 Valve High Pressure Low Pressure RETURN STROKE X-Block

October 30 – November 3, Power Steering Tube Bender - CURRENT OPERATING DATA WITHOUT X- BLOCK ∙ 25 double-acting cylinders with 2-way valve control ∙ 7.82 cycles/minute ∙ 105 psig in pressure to Bender ∙ Measured rate of flow – 22scfm CURRENT OPERATING DATA WITH X-BLOCK BASED RETURN AIR RECOVERY SYSTEM ∙ 25 double-acting cylinders with X-block return air control - 2-way valve power stroke air ∙ 2 return air storage collectors (Transair aluminum pipe) with reusable fittings ) ∙ 95 psig inlet pressure to Bender ∙ Measured rate of flow – 5.94 scfm ∙ Compressed air savings: ∙ 10 psig – same power ∙ scfm – 73%

5.94 scfm 95 psig Running with X-Block - Running without X-Block 105 psig 22 scfm Without X-block

SUMMARY: Benefits from installing the X-Block System Use less compressed air, 50 to 60% Ability to probably lower system pressure and retain same load and cycle times Potential to increase cycle time with same load Stabilize operating pressure Eliminate need for “cushion air” Replace slow cycle single acting cylinder with double acting – no increase in compressed air use.

Optimizing Air Operated Double Diaphragm Pumps Control Pressure Control Cycles (Back Pressure) Automatic Shut Off Controls -Convert to Electric-

Air Operated Diaphragm Pump Compared to Electric 2” Diaphragm Pump / Water/ 40 foot head 75 gallons per minute 75 psig inlet pressure 70 cfm $4,056 per year Electric Pump 3 Horse Power $780 per year

With “MIZAIR” on:  At the same input pressure, the compressed air usage fell 36% to 50%  The stroke rate fell  The product capacity per stroke increased  The average product flow per scfm increased significantly  Product flow per unit of energy increased from 50 to 100%  Run quieter – low exhaust  Pressure controlled stroke stop – not mechanical  Reduced maintenance costs

AIR SAVINGS OPPORTUNITIES IN COMPRESSED AIR BLOW OFF SYSTEMS

Two Types of Efficiency Nozzles Control/Dispersion and Venturi Amplifiers Dispersion Control Nozzles

GENERAL GUIDELINES Use high pressure only as a last resort Use high pressure only as a last resort All blow-off air should be regulated to the lowest effective pressure – higher pressure means higher flow, which may not be needed All blow-off air should be regulated to the lowest effective pressure – higher pressure means higher flow, which may not be needed Use venturi air amplifier nozzles whenever and wherever possible – this will usually reduce blow-off air at least 50%, freeing up more air flow for other applications. Use venturi air amplifier nozzles whenever and wherever possible – this will usually reduce blow-off air at least 50%, freeing up more air flow for other applications. All blow off air should be controlled to shut off (automatically) when not needed for production. All blow off air should be controlled to shut off (automatically) when not needed for production.

80 psi 32 cfm ¼” tube 12” long 32 cfm Electrical Energy Cost = $1862 per year 10 cfm 80 psi ¼” tube 12” long 250 cfm Venturi Amplifier Nozzle Adjustable Electrical Energy Cost = $581 per year Venturi Amplifier Nozzles Induce ambient air into the air stream Straight tube compared to Venturi Nozzle COMPRESSED AIR BLOW OFF’S

PRIMARY BLOW OFF CONTROL CRITERIA Thrust from pressure (psig) is required to loosen the object to be removed Thrust from pressure (psig) is required to loosen the object to be removed Thrust dissipates very rapidly once the air has left the “blow off” device Thrust dissipates very rapidly once the air has left the “blow off” device Volume of total air (cfm) – (compressed air plus induced air) is critical to carry the material away within the air stream. Volume of total air (cfm) – (compressed air plus induced air) is critical to carry the material away within the air stream. On all blow off devices, the higher the compressed air inlet pressure, the more compressed air is used. On all blow off devices, the higher the compressed air inlet pressure, the more compressed air is used. Identify the optimum entry pressure and control is at that point. Additional pressure uses more air with no process improvement. Identify the optimum entry pressure and control is at that point. Additional pressure uses more air with no process improvement. When the blow off process does not have to be continuous, install controls to operate only when required When the blow off process does not have to be continuous, install controls to operate only when required

LOW PRESSURE BLOWER GENERATED BLOW OFF AIR Electrical Energy Cost to produce psig = $43,000 Electrical Energy Cost to produce psig = $26,000 Electrical Energy Cost to produce psig = $18,000 Electrical Energy Cost to produce psig = $ 8,000

Compressed Air Knife 12” 3 cfm Per Inch = psig 7 HP = 5.6 kW.05 kWh $2452 / year Blower Air Knife 12” 3 cfm Per Inch = psig 1 HP =.8 kW.05 kWh $350 / year

EMERGING TECHNOLOGY CONTROL CABINET COOLING

WILL NOT COOL BELOW AMBIENT Heat Pipe Cooling

VORTEX TUBE REFRIGERATION CABINET COOLER Cold Air -10 o F Compressed Air Supply 90 psig – 70 o F Hot Air from Vortex Tube 230 o F Vented Hot Air from Cabinet Cabinet Air Exhaust Compressed air temperature Drop 60 to 90 o F

THERMOSTATIC AUTOMATIC SHUT OFF Vortex tube – cools quickly Vortex tube – cools quickly Unlimited starts & stops; just shut off / turn on Unlimited starts & stops; just shut off / turn on Muffler Thermostat Cabinet Wall Normally Closed 2 way solenoid Air Filter Air Supply Ducting 8’ long 110 Volt

THERMOELECTRIC REFRIGERATION CABINET COOLERS Average cooling 10 – 30 o F (max possible 40 o F) below ambient Works in a totally sealed cabinet

Comparison of various types of control cabinet cooling Based on 1500 Btu/HR auxiliary cooling (metal cabinet 4’ wide – 1’ deep – 4’ high (135ºF maximum temperature) Compressed air Open blow Ambient air fan Refrigeratio n Vortex tube Heat pipe Thermoelectric refrigeration Initial cost$20$200$700$525$850$1,800 Installation$20$150$200 Annual maintenanc e $ - 0 -$20$150$20$50$20 Annual electric operating cost $23,536$331.77$306 $832 or less* $35.42$ Life expectancy Infinite5 years2.3 yearsInfinite 20 years Limits Will not work above 90ºF Will not work above 70ºF May not work at 135ºF Can work up to 200ºF – up to 80 o F or more temp drop Will not work above 90ºF unless water cooled Will work up to 140ºF Btu/HR maximum cooling available today – 15 to 20 o F temperature differential from ambient *Vortex tubes, properly installed with appropriate temperature controls

THANK YOU QUESTIONS? QUESTIONS? WE WILL HAVE MORE INFORMATION AT BOOTH 404 WE WILL HAVE MORE INFORMATION AT BOOTH 404