System Assessments

This article explores the distinction between standard system controls and holistic controls for highly efficient process cooling systems. Examples of high performance controls features and implementations are provided, and screening questions are listed for initial investigation of existing system and potential new systems.

Heat recovery opportunities have resulted in the largest amount of savings of our common projects our industrial energy management teams have implemented.  It is not the easiest type of project to implement but the amount of savings and the reduction of emissions makes this project very worthwhile.
When the topic of discussion is making ice cream, the first thing that comes to mind isn’t heat, but at Nestlé’s Ice Cream factory in Tulare, California, heat is recovered from air-cooled air compressors to heat process water. “Right out of the gate, everything is pneumatic,” explains Tom Finn, Project Engineer with Nestlé Ice Cream Division. “Air cylinders and air driven motors, the process piping valves which divert, route, stop/start, and mix process fluids, our packaging machinery including rejection, cleaning and vapor removal processes, all of these rely on compressed air.
There are several pieces of information that your cooling system specialist will need in order to properly engineer and build a cooling system for your new air compressor. There are many types of air compressors and each has different requirements of the cooling system in order to operate correctly. This article will take the mystery out of some of the terms and specifications for your cooling system.
The rise in energy prices is an unwelcome reality in today’s manufacturing and business environment. And while the rate of price increases for natural gas, heating oil and electricity may vary from year to year, the upward trajectory is clear. Energy cost reduction strategies are vital to staying competitive. Compressed Air Best Practices® Magazine recently discussed heat recovery, from industrial compressed air systems, with the Compressed Air and Gas Institute’s (CAGI) Technical Director, Rick Stasyshan and with CAGI member – Werner Rauer of Kaeser Compressor. Their inputs should provide you with some insight in energy-saving technology.
When compressed air is generated, heat is inevitably produced as a by-product. Anyone looking to enhance efficiency can use this heat and increase the efficiency of compressors to about 95 percent as a result. To achieve this, there are easy-fit heat exchangers which can be fitted to existing air compressor stations. This investment often pays for itself within less than a year.  
There are six basic types of cooling systems that you can choose from to meet the cooling needs of your load. Each one has its strengths and weaknesses. This article was written to identify the different types of cooling systems and identify their strengths and weaknesses so that you can make an informed choice based on your needs.
Temperature control of the musts during the fermentation process is required for the production of high quality wines. Alcoholic fermentation is the chemical reaction in which yeast is used to transform the natural sugars of the fruit into alcohol. The heat generated by this exothermic reaction has to be managed. If must temperatures are allowed to reach the 85°F to 105°F range the reaction will be stopped. This results in high sugar content and an unstable product that requires the addition of sulphur dioxide (SO2) to allow it to be stored without spoiling. In general, optimal fermentation temperatures are 65°F - 68°F for white wines and 77°F for red wines.
Its simple physics that compressing air gives off heat. The heat energy is concentrated in the decreasing volume of air. To maintain proper operating temperatures, the compressor must transfer excess heat to a cooling media before the air goes out into the pipe system. As much as 90 percent of that heat can be recovered for use in your operation. If you can supplement or replace the electricity, gas or oil needed to create hot water for washrooms, or direct warm air into a workspace, warehouse, loading dock, or entryway, the savings can really add up.
Industrial plants are major consumers of water. Water is used in many processes. Sustainability projects focus on reducing the consumption of water and the energy-costs associated with cooling water so it may be effectively used.
It is widely recognized that compressed air systems account for ten percent of all electricity and roughly sixteen percent of U.S. industrial motor system energy use. Seventy percent of all manufacturing facilities in the United States use compressed air to drive a variety of process equipment.