2MARKET OVERVIEW Venturi Replacement Application SpecificsSystem SchematicsComparison ExamplesGround RulesMajor CompetitorsBest Approach to Attack the MarketEconomic Evaluation Spreadsheet
3MARKET OVERVIEW Vacuum Venturis Used for many yearsOEM applicationsSimple, small, remote vacuum usesCompact, simple, cheap, no moving partsJust plug into your existing compressed air line
4Very Simple … If you stop here MARKET OVERVIEW Vacuum VenturisAir CompressorMotive Air for VenturiVery Simple … If you stop here
5Venturis have Huge Disadvantages End Users – Operating CostsOEM using Venturis will look weak every timeMany Vacuum Venturi applications benefit greatly by replacement with vacuum pumpsWe’ll show you when, how and why vacuum pumps or blowers are the best choice
6APPLICATION SPECIFICS Venturi Operating Principle Motive air from compressorEntrained air is pulled through nozzlesSuction created at opening of each stageCreating vacuum at system inlet
7VISUALIZATION TECHNIQUE (using Frank’s new “Dream” Ferrari) Going warp speed in a 35 mph zone, Led Zeppelin splitting his eardrums, Frank cracks the front windowsCigar smoke from his illegal Cuban cigar is sucked out the window, tangled in the flowing hair of his buxom, blond bimbo
9VISUALIZATION TECHNIQUE Key Point . . .Massive air flow is required to develop a small amount of suction flow and vacuumThe Process is extremely inefficient
10Rietschle Success Story Application: Vacuum for packing machinesReplace: 27 Gast rotary vane pumps (24”HgV)Under Consideration:A. PIAB VenturisB. Duplex 20 HP liquid Ring vacuum systemC. Rietschle CLFEH-501 duplex pump system (with two 20 HP motors) or a Rietschle VCEH-160 triplex system with three 10 HP motors).
11Rietschle Success Story (cont.) User’s sister company used PIAB venturisRecommended replacement of high-maintenance Gast vacuum pumps with PIAB ejectorsCustomer was receptive to an economic analysisAnalysis uncovered huge energy and cost savingsRietschle secured a significant system orderRietschle system saved approximately:40% power compared to the individual Gast pumpsOver 90% in power compared to the PIAB venturis, and provided more than double the air flow to their system!
12Economic Evaluation Example Given Conditions:End User has (25) PIAB model MLD-100 vacuum venturis operating on his existing machines. He requires 18”HgV on his machines for pick & place operations. Current installed capacity is 62.5 scfm (PIAB literature shows that each MLD-100 can deliver “HgV X 25 = 62.5 scfm).Customer Requirements:Customer wants to add additional capacity and will need an additional 25 scfm. His current air compressor is fully loaded, so if he uses vacuum venturis, he will need to add additional air compressor capacity.
13Economic Evaluation Example (cont.) 1. Based on PIAB literature, customer will need to add 10 additional venturis to obtain 25 scfm (25 scfm ”HgV = 10 venturis).2. Calculate air compressor airflow to operate 35 venturis (25 existing venturis plus 10 new venturis). Per published PIAB literature, each venturi will require approximately 13 scfm of air compressor capacity. 13 X 35 = 455 SCFM.3. Estimate power consumption to produce psig. Either obtain actual compressor and motor size from a vendor, or use 4.0 scfm/HP as an estimate 4.2 = bhp.
14Economic Evaluation Example (cont.) 4. Estimate cost of power. Assuming a power cost of $0.10/kw-hr, and 5840 hours per year operation (two shifts, 365 days per year), annual operating costs of the above system would be:$/Yr = HP X .746kW/HP X $/kW-Hr X Hrs/Yr= X .746 X $0.10 X 5840= $42,917 per year operating costs for Venturis.
15Economic Evaluation Example (cont.) Select Rietschle vacuum pump to do the job.a. Convert SCFM to ACFM. [ ”HgV (11.92”HgA)] ACFM = SCFM X (29.92 / “HgA) ACFM = 87.5 X (29.92 / 11.92) ACFM = ACFMb. For 18”HgV, you could use a duplex VTB-250, dry running rotary vane vacuum system. Each pump has a capacity of ”HgV and uses a 10 HP motor. Two pumps running together will actually provide much more than the required capacity. By providing a central system with air receiver and vacuum switches, one pump would probably handle the requirement most of the time. For the purposes of this example, be “generous” and assume both 10 HP motors need to run continuously, for a total power consumption of 20 HP. (Actual power consumption would be closer to 10 Hp than 20 HP).
16Economic Evaluation Example (cont.) 6. Calculate Power Cost for Rietschle System $/Yr = HP X .746kW/HP X $/kW-Hr X Hrs/Yr= 20 X .746 X $0.10 X 5840= $8,713 per year operating costs for Rietschle System. Annual Operating Cost Savings Using a Rietschle System$42,917 - $8,713 = $38,484 Cost SavingsThis does not even include any capital cost evaluations. If you include the cost of the initial compressor system (usually much larger and more costly than a Rietschle Vacuum System), the evaluation often looks even better. Payback can sometimes be a matter of months in energy savings alone!
17Rules of Thumb Typical motive air pressures are from 60 – 100 psig Compressors provide about 4.2 scfm per 100 psigCompressor systems can be ball-parked at $350/HPDepending on vacuum level, Rietschle vacuum pumps can be from 3 – 10 times more efficient than vacuum venturisVenturis are reasonable for very small, isolated vacuum requirements if excess compressor capacity already existsVenturis are a terrible choice for high capacity requirements
18Rules of Thumb Venturis become less efficient at higher vacuum levels Venturis are one of the most inefficient ways to produce vacuumEfficiency drops as motive air pressure decreasesPaybacks can often be just a few months, especially when higher vacuum levels are requiredVacuum systems are usually smaller and less costly than the compressors required to operate venturis
20Venturi Advantages / Disadvantages Venturi DisadvantagesLow initial costUltra-high operating costsCompact (ignoring compressor)Low efficiencySimple operation (if you ignore compressor system)Requires separate compressor, piping, valves, traps, regulatorsGood for very small demandsPoor choice for higher demandsCompressors must be oversized to insure proper operation
21Rietschle Advantages Huge energy and cost savings Very rapid return on investmentNo separate compressor system to purchase and installSystems can run multiple machinesOn-Line standby capacityOEM’s can promote higher efficiency vs. their competition
22Best Approach to Attack the Market Sell to the OEMSell him on efficiency and operating cost benefits to his customersSell Users on concept of “Total System Cost”Additional sales & profitVacuum pumps do a better job – more flexibleCustomer can free up existing air compressorsThe “KEY” is a good economic evaluation
23Best Approach to Attack the Market Sell to the End UserEfficiency and operating costsLook for multiple machines and/or large requirementsLook for higher vacuum levels, where venturis are very inefficientAsk how he is doing on compressor capacityCustomer can free up existing air compressorsAsk about future expansions and new machineryThe “KEY” is a good economic evaluation