Engineered Compressed Air Nozzles and Utility Rebates

When EXAIR started to manufacture compressed air products, we created a culture in making high quality products that are safe, effective, and efficient.  Being leaders in this industry, we created a program, the Efficiency Lab, to compare blow-off devices with EXAIR products in noise levels, flow requirements, and force measurements.  With calibrated test equipment, we compare the data in a qualified report to share with our customers.  This information can be helpful to determine the total amount of air savings and safety improvements that EXAIR products can offer.

Flat SANs 1in
Zinc Aluminum models are suitable for general purpose blow off (left) and 316SS models are specified for food/pharma and high heat applications.

In conjunction with the Efficiency Lab, we created a Cost Savings Calculator.  It is a quick way to view payback periods and annual savings when using EXAIR products.  As an example, I used a 1” Flat Super Air Nozzle, model 1126, and compared it to a 1/8” open pipe.  (The reason behind the comparison is that the model 1126 can screw onto the end of the 1/8” NPT pipe.)  With an operation of 24 hours/day for 250 days a year, the amount of air used by an 1/8” open pipe is near 70 SCFM (1,981 SLPM) at 80 PSIG (5.5 Bar).  The model 1126 has an air consumption of 10.5 SCFM (297 SLPM) at 80 PSIG (5.5 Bar).  By putting the information in the Cost Savings Calculator, it determined that the ROI was in 2.1 days.  The annual savings was $5,355 USD per year.  Imagine if you replaced ten blow-off spots in your facility, the amount of money that could be saved.  Here is the worksheet below:

flat 1

The people that started to notice the savings were the utility companies that make electricity.  Depending on your location, electrical suppliers initiated a rebate program to use engineered nozzles in your facility.  Similar to other energy saving rebates, like LED light bulbs and high efficiency furnaces, the electrical providers notice a big savings when using EXAIR products.  If you qualify, the total cost to purchase and implement the EXAIR Super Air Nozzles are reduced.(Even if a rebate program has not been implemented in your area, the idea of saving energy and compressed air makes it very profitable and environmentally sound in changing over to EXAIR products).

To see if your utility offers rebates on compressed air optimizations, go to the DSIRE database. This database is easy to search and informative.

For Example, here in Ohio Duke Energy has a Prescriptive Incentive Program for its customers. The Prescriptive Incentive Program makes it easy for Duke Energy customers to receive an incentive for their natural gas and electric energy efficiency projects. Prescriptive Incentives are energy efficient measures paid per-unit, reimbursing the customer up to the total cost (including materials and labor) after the measures have been installed. See the image below for their incentives for using Engineered Nozzles;

capture.jpg
Ohio Duke Energy Prescriptive Incentive Program

https://www.duke-energy.com/business/products/smartsaver/industrial-equipment

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process and save you money, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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Video Blog: EXAIR Efficiency Lab

The video below is a brief introduction to the EXAIR Efficiency Lab, a free service provided by EXAIR for customers within the USA and Canada.

If you have a single point blowoff that does not have an engineered nozzle, or if you have a wider format blowoff, manifold or home-made drilled pipe, contact an Application Engineer with EXAIR and let us help you to reduce your energy waste. Following are some examples of product where we have helped to save some serious air and reduced noise levels which heightens employee comfort.

Non-engineered blowoffs
Drilled and soldered copper pipe.
Custom manufactured inefficient pipe blowoff

 

The EXAIR Efficiency Lab

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

Efficiency Lab Provides Specific Benefits

My Ruck sack w/ 20 lb. weight and a flag for the team to carry.
My Ruck sack w/ 20 lb. weight and a flag for the team to carry.

This weekend, myself and many others are going to be participating in an event held all over the country, the Go Ruck Light event.  This test of toughness (mental and physical) is put on by former military personnel and it is based around one of the things they do a lot of at the beginning of their military training.   This is a 7 to 10 mile event that will take up to 4 hours to complete.   It is not like a race or any other obstacle event that we have ever done.   This is an event where the leader, or Cadre, will lead you through the miles and many physical exercises along the way all while carrying a 20 lb weight in a ruck sack on your back.   This not only tests individuals but it also requires the entire group to work as a team to ensure everyone finishes and everyone is together.

While I feel that I am under-prepared for this event physically, my mind is prepared to find out just how much I really can do and it will be at the end of the test that I realize the benefits.

Not many of the tasks I am responsible for at EXAIR require that kind of physical toughness and some of them require the mental toughness. But one instance I am always prepared for is the customer that calls and thinks they have the weirdest application and that there is nothing to solve it.   We actually have this experience quite a bit and it helps make what we do more interesting and fun.  With our diverse background and extensive knowledge, chances are we have experienced the application or we have seen something that is very close.  This helps us to be specific when recommending a solution.

EXAIR feels that the best solutions can also provide information on air and dollar savings as well.  The best savings information can be provided if our customers are willing to provide us details about their current application, and there is no better way to provide us the details than to take advantage of our Efficiency Lab. It is a free service letting you to send in a sample of your current blowoff product (typically homemade nozzles, open tube or pipe, snap together coolant hose, etc.), in return we will test it for you with our calibrated equipment and provide you a detailed report on air volume, force and noise. Then you will know the specific benefits of your recommended solution.

EXAIR's Efficiency Lab is a free service to all US customers.
EXAIR’s Efficiency Lab is a free service to all US customers.

The fact is, we go into every conversation with the mentality of only providing solutions.  If we can’t provide it, we will try to direct you to someone that can.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Where Does 25 Cents For 1,000 Standard Cubic Feet Of Air Come From?

Wasting compressed air 2

Being an Application Engineer at EXAIR you tend to do a good amount of return on investment (ROI) calculations.   This is mainly to tell customers just how fast installing an EXAIR product on their system is going to pay its purchase price back and start saving them money.

In order to do these calculations there are several variables we must know.   The list is below.

  • Cost of EXAIR Product (This is an easy one for us to know.)
  • EXAIR Product Consumption (Another easy one!)
  • Current Product Consumption (If this is an unknown, we will test it for free!)
  • Cost of Compressed Air / 1,000 SCF (This is the most common unknown.)

With these four variables we can calculate the amount of air and the amount of money the EXAIR product will save over an existing non-engineered blowoff.   Let me address the two variables which have to come from you, the customer.

Current Product Consumption – If this value is not known please don’t guess at it.  We offer a free service which we refer to as our Efficiency Lab where you send us in your existing blowoff device and we will test it for force flow and noise level.   If you don’t know what pressure you are operating the piece at we will help you find out how to get that and then we will test our products at the same pressures.   This way you get a true apple to apples comparison.   Then, once we are done testing, you will get a recommendation from us in a formal report as to what EXAIR product will best replace your existing product.  Then we will pay for return shipping of your blowoff device back to you. So, if you don’t know how much air you are currently using then give us a call.  We will figure it out for you.

Efficiency Lab
The EXAIR Efficiency Lab is FREE!

Cost of Compressed Air/ 1,000 SCF – This is more often than not, the unknown variable in the equation.  The good news is there is a general standard assumption of twenty-five cents per 1,000 Standard Cubic Feet of compressed air.   This works out to be around 8 cents per kW/hr.  So even if you don’t know what you pay to compress the air, if you know what you are paying per kilowatt hour for your energy then we can calculate within reason what it costs for you to generate your compressed air. For reference, 8 cents per kilowatt-hour falls between the average US cost per kilowatt hour for commercial end-users (10.7/kWh) and industrial end-users (6.9/kWh).*

The best part of all is…EXAIR has a calculator available right on our website which provides air and dollar savings per minute, hour day and year as well as a payback in days for the EXAIR product purchase. On top of that, any step along the way that you aren’t sure of, we will help you out for free, even testing your product!

In case you would like to see the math, the formula used is below.

Basic Equation To Go From Cost Per kiloWatt Hour to Cost Per 1,000 Standard Cubic Feet of Compressed Air
Basic equation to go from Cost Per kiloWatt Hour to Cost Per 1,000 Standard Cubic Feet of Compressed Air

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

*latest U.S. EIA report here