Consumption/Air Flow Monitoring

Compressed air is a common utility used in various industrial and commercial applications. Monitoring the consumption and flow of compressed air can provide valuable insights into the efficiency of compressed air systems, help identify potential leaks or inefficiencies, optimize energy usage, and reduce operational costs. Here are some common applications for compressed air consumption and flow monitoring:

Energy Management: Compressed air systems can account for a significant portion of energy usage in industrial facilities. Monitoring compressed air consumption and flow can help identify areas where energy efficiency improvements can be made. For example, by identifying and fixing leaks in the compressed air system, unnecessary energy waste can be avoided, resulting in cost savings and reduced environmental impact.

System Performance Optimization: Monitoring compressed air flow can help optimize the performance of compressed air systems by providing real-time data on flow rates, pressure levels, and other parameters. This data can be used to fine-tune the operation of compressors, dryers, and other components of the compressed air system to ensure they are operating at optimal levels, thereby improving overall system efficiency and reliability.

Maintenance and Troubleshooting: Monitoring compressed air consumption and flow can aid in identifying and diagnosing issues in compressed air systems. For example, sudden changes in consumption patterns or flow rates may indicate a leak or a malfunctioning component. Early detection of such issues can help prevent system downtime, reduce maintenance costs, and extend the lifespan of equipment.

Leak Detection: Compressed air leaks are a common issue in compressed air systems, and they can lead to significant energy waste and increased operational costs. Monitoring compressed air flow can help detect and locate leaks in the system by identifying abnormal drops in pressure or flow rates. This enables timely repairs to be made, preventing further energy waste and reducing operating costs.

Process Optimization: Compressed air is often used in various industrial processes, such as pneumatic tools, packaging, and drying applications. Monitoring compressed air consumption and flow can provide insights into the performance of these processes, helping optimize process parameters and reduce compressed air usage, which can result in cost savings and improved productivity.

Environmental Compliance: Monitoring compressed air consumption and flow can help industries comply with environmental regulations related to energy usage and emissions. By accurately measuring and reporting compressed air usage, companies can demonstrate their commitment to sustainability and environmental stewardship.

Billing and Cost Allocation: In some cases, compressed air may be supplied to different departments or areas within a facility, and accurate monitoring of compressed air consumption can be used for billing and cost allocation purposes. By tracking compressed air usage at different points in the facility, companies can accurately allocate costs and ensure fair billing among different departments or customers.

Additional Applications

Wastewater Treatment : Monitoring and adjust the air flow into aeration tanks to control the critical D.O. level.

Metals Recovery: Air flow rate is critical in forming bubbles during the process that capture precious metals that otherwise are not recoverable.

Spray Drying Air flow monitoring, so that components dry uniformly in white appliances, pharmaceutical, food processing, fertilizer and chemical industries.

Brewery Malt Germination: Air flow monitoring for energy saving.

Remediation Meter the air intake used to detect contaminated soil.

Pulp and Paper Improve product quality by monitoring drying air flow

Fuel Cells Air flow monitoring to control the efficiency of fuel cell power plants.

Powder Painting Monitor air flow, including turbine air, atomizing air and shaping air to control paint quality using robotics. .

Heat Treating Air flow monitoring in heat treating furnaces to improve quality.

In summary, monitoring compressed air consumption and flow can provide valuable insights for optimizing the efficiency of compressed air systems, identifying and resolving issues, reducing energy waste, improving operational costs, and supporting environmental sustainability. It is an essential tool for industries and commercial facilities that utilize compressed air in their operations.

Monitoring the use of compressed air within a facility.

To determine the optimum number of compressors that need to be in operation at any given time so that the facility load is satisfied, a measuring station that includes a controller (D300) and a consumption sensor (Sigma 401) is installed so that the consumption of compressed air is monitored continuously and automatically determines the optimum number of compressors to handle the facility demand.