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| Volume 2, Issue 10
Upgrade Your Compressed Air Blow-Off System
for Energy Savings
Are you considering upgrading
your existing compressed air blow-off system? Need more power or
shorter cycle times? High-efficiency centrifugal blowers can provide
energy savings as well as a performance upgrade to your existing
compressed air blow-off system for substantially less than your current
system’s operating costs.
What is your air blow-off system wish list?
• More power?
• Faster conveyor line speed?
• Better drying rate?
• Lower electrical cost?
In today’s competitive
business environment, both large and small manufacturers are striving
towards reducing their cost base. Making a fresh appraisal of
compressed air as well as inefficient blower-driven air blow-off
systems can make real economic sense.
Re-engineering is not just a
trendy buzzword, but a practice that has proven beneficial in
modernization or upgrading of existing industrial processes which are
using compressed air. Enhanced capital allowances (ECA) are the carrot
that the Government has extended to encourage investment in new
Data gathered from case studies* of programs by the United States Department of Energy’s Office of Industrial Technology suggests excellent paybacks based on energy savings alone:
|Type of Plant
||Annual Cost Savings ($US)
**As percent of initial electricity usage
Gathered from the U.S. Department of Energy's "Motor Challenge
Program." Savings is relative to energy consumption prior to the
downsizing of air compressor motors.
Blower driven blow-off
technology is simply more efficient than compressed air; it can provide
staggering savings. Depending on your conditions, the savings may be up to 90%,
meaning that an investment in a blower driven solution pays for itself
in a very short period—four or five months is not uncommon.
A second payback is
productivity increase—more widgets-per-hour processed. This
increase in productivity can be considerable and by itself could
justify the investment in upgrading.
Whether your requirements have
changed in terms of the quantity or quality of your blow-off system
requirements, upgrading is a cost-effective and reliable solution.
Air Blow-Off System Selection & Plant Productivity
Selection of a high efficiency
industrial blower will mean higher flow or pressure allowing for more
widgets-per-hour to be processed. How much is a five or ten percent
productivity increase worth?
Compressed Air Systems vs. High Efficiency Blowers
The bottom line to a
manufacturing plant owner/operator is the cost of blow-off air per SCF.
The cost per SCF of air is dependent upon the efficiency of the
compressed air system or blower system used to produce the air.
When comparing compressed air
blow-off systems to high efficiency blower systems, one needs to
compare annual electrical cost and return on investment (ROI) for
various air blow-off systems available. Too often only the initial cost
is considered, not the day-to-day operating costs.
For comparison we will consider
three typical compressed air delivery systems: the homemade drilled
pipe; single bore or flat fan nozzles mounted on a pipe; and the bar
type air knife. When operating at 60 psig, the 18-inch pipe systems
will each flow approximately 290 SCFM and the bar air knife with a
0.003” gap will flow 130 SCFM. Approximately 72 compressor
horsepower are required to produce a flow of 290 SCFM. Similar blow-off
results can be achieved with a 75% efficiency blower, requiring only 5
horsepower to flow 324 SCFM.
At the US average electrical
cost of $0.083 per kW-hr, the power cost for the 5-HP blower equals
$1,358. For the 72-HP compressor, the power cost is $21,399. The power
cost represents approximately 65% of the total cost of the compressor
over a 7-year period. In addition to power cost, annual maintenance
expenses add an additional 20% to overall cost.
Upgrading from a 72-HP compressor to an AirPower™ blower yields an annual savings of $20,000 in electrical costs. This is not a one-time savings; it is year-after-year. For a 7-year period the savings would be $140,000.
Vortron’s “New” Home Page
Visit our “NEW” Home Page, www.vortron.com, for more extensive information on AirPower high-efficiency blowers and air blow-off systems.
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