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A Cement Plant Bags $180,000

The 1,500 HP of Compressed Air that was running continuously couldn’t keep adequate pressure to the diverter valves, creating occasional dumps of the silo contents. This productivity problem created a clean-up mess requiring significant operator attention and required product reprocessing …. Read More

Case Studies

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Avoiding Pneumatic Malpractice

A cement import terminal had a multitude of problems that were causing production interruptions and environmental releases

of dust due to poor air quality and low air pressure....Read More

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Bottler Gets a Quick Pop in Profits

The bottler’s maintenance department made improvements to the air system

using discretionary money since they had no profit and loss responsibility. Over the years, changes in the....Read More

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The Financial Impact of Compressed Air Projects

How expensive is compressed air?  Where does it impact the bottom line?  Can any of this money be recovered and if so, is there

a reasonable payback?  What are the key factors in....Read More

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Not Your Ordinary Air Systems - Gypsum/Wallboard Plants

 

A wallboard plant had two systems; the board mill compressed air system and the rock mill compressed air system. Each system had two 100 hp compressors all of which constantly overheated. When they did, they had to scramble to turn on a machine manually every time a unit shutdown. Three units ran the plant so….Read More

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The Hidden Cost of Compressor Company Audits

 

Plant personnel often go to the com-pressor company used to install the compressors when getting advice on how to run, improve or optimize their compressed air system. After all, that vendor and their equipment were originally selected based on their perceived ability to make the system run reliably at….Read More

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Kick the Compressor Habit

“It seemed that every time the plant added anything to their pro-chess that used air, they were buying new compressors. Their guts told them they probably did not need them, but they did not know what else could be done. They also suspected that their operating costs were going up unnecessarily, but they were not sure….Read More

 

Magazine Publication

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Bearing Cooling: A Common Misapplication

Bearing cooling is often applied to overheating bearings, as well as marginal bearings in hot environments. Typically, the operator grabs the nearest compressed air hose and ties it in some.....Read More

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Compressed Air System Drawings

One strategy that is overlooked is just drawing the details of whatever aspect of a system you are looking at. It is fairly common to see a misdiagnosis of some particular technical issue.....Read More

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Correctly Solving Low Air Pressure Problems

Pressure problems were the reason our very first customer ever called us. This cement plant had an issue where lower air pressure intermittently affected the operation causing....Read More

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The Challenges of Compressed Air Audits in Chemical Plants

Chemical and petrochemical facilities are often motivated differently than other industries. There is an even greater emphasis on safety, process stability and system reliability. While these plants like projects that reduce cost, they are much more interested in projects that enhance reliability while reducing….Read More

 
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Detailed Design - An Ounce of Design is Worth a Pound of Project

Insufficient focus at the design phase will kill a project. In one aerospace project, insufficient detail was paid to the physical size of the air compressor. The compressor didn’t fit in the allocated space—requiring the extension of the building, and costing tens of thousands of unbudgeted dollars. That had a significant.….Read More

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Four Principles for Sustaining Savings

 

When Compressed Air Consultants was starting, in 2003, we were approached by a company experiencing significant problems with their compressed air system.  They had compressed air pressure problems causing production interruptions.  They had moisture issues causing all kinds of havoc throughout the facility and appeared to be….Read More

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New Air Compressors Aren't Always the Answer

The plant originally ran on three air compressors. However, ongoing efforts had gotten them to the point where two air compressors could run the plant. It also became clear that no one would be blamed for issues uncovered later on given the lack of information available. Since this plant had bigger issues to address beyond....Read More

Solving Compressed Air Problems for the Long Term

Compressed air is a major expense in many plants, costing directly for equipment and power and indirectly through reduced productivity and scrap product. When your compressed air costs become too high, or when the air system doesn’t seem to be operating as efficiently as it could, finding the right solution .….Read More

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Improvement by Leak Detection and Repair

 

Leaks can increase the already high energy cost of running your bulk solids plant's compressed-air system and reduce its efficiency. This article  explains how implementing a leak detection and repair program for your compressed air system fits into an overall system optimization process….Read More

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System Assessments Part 1 - Petrochemical Plant Optimizes Centrifugal Compressors

This large petrochemical facility employs 400 employees and contractors. The site covers an area of almost 900 acres. Natural gas liquids are used as a feedstock at the plant to manufacture ethylene, the world’s most widely used petrochemical. The ethylene is then converted into polyethylene and....Read More

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System Assessments Part 2 - Petrochemical Plant Optimizes Centrifugal Compressors

This large petrochemical facility employs 400 employees and contractors. The site covers an area of almost 900 acres. Natural gas liquids are used as a feedstock at the plant to manufacture ethylene, the world’s most widely used petrochemical. The ethylene is then converted into polyethylene and....Read More

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Reframing System Improvement Cost Decisions - Part 1

Compressed-air systems are essential to many powder and bulk solids handling processes. However, when confronted with compressed-air system issues, instead of tackling the problem and repair costs head-on, many plant managers look for shortcuts even though this can cost more money in the long run.....Read More