Post on 18-Jul-2020
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Compressed Air Usage
Air Compressor
10% of industrial electricity used to power air compressors
7,500 kWh€498m per annum10%
A Typical Rotary Screw Air Compressor
Represents by far:
The single largest cost associated with compressed air
Example Case Study
64 m³/min360 kW(2260cfm)
CapacityInstalled
4 x 90kW Air Compressor1 x Refrigerant Air Dryer1 x Air Receiver2 x Air Filters8 x Drain Valves
Hours per Annum :6000 Operational2424 Non-Operational
2 weeks annual Shutdown
Example case study
€21841€14 561
€109 208
AnnualCost
Key Savings Opportunities
Optimisation of:
PressureControlLeakageFilter Elements
Energy Savings PotentialExample Case Study
Energy Savings PotentialExample Case Study
Energy Consumption - Pressure
1.5%
€1 639
Energy Consumption - Pressure
Designing and operating a system at unnecessarily high pressures will waste energy and increase running costs
PressureUtilising a number of individual pressure switches forces the system to produce compressed air at a pressure above that required.
140
120
100
80
60
40
400
350
300
250
200
Flow
(l/s
)
Pressure (bar)
Pow
er (k
W)
4 8 9 10 115 6 7
Power
Flow
Energy Consumption - Pressure
Energy Consumption - Pressure
1
2
4
3
5
Conventional Cascade
100%Air Demand
+6.25%
+5.00%+3.75%
+2.50%+1.25%
Additional cost ofinput power aboveassumed optimum
System Pressure
Enercon S5
Air Demand 100%
7.0
7.5
8.0
8.5
Optimised System Pressure
Additional cost ofinput power aboveassumed optimum
bar
6.5
+0.5% +0.5% +0.5% +0.5% +0.5%En
erconS5
12345
CAP!!
PressureEnergy Consumption - Control
5.2%
€5733
Energy Consumption - Control
Supplying an air main at high pressure is costly.
Additionally, any losses arising from leaks in the system would reduce as air pressure is regulated downwards
MANAGEMENT SYSTEMS
Selects the most efficient combination of compressors to satisfy demand
AIR
DEM
AN
D
HIGH
LOW
AIR DEMAND
min
7.6
7.5
7.4
7.3
7.2
7.1
7.0
6.9
6.8
6.7
AIR
SYS
T EM
PR
ESSU
RE
( bar
)
Conventional
DEMAND
321
max
7.6
7.5
7.4
7.3
7.2
7.1
7.0
6.9
6.8
6.7
Managed
AIR
SYS
TEM
PR
ESSU
RE
( bar
)
1 2 3
min DEMAND max
SYSTEM PRESSURE
5 - 10% Energy Saving Potential
COMPRESSOR UTILISATION
1
3
2
10 - 15% Energy Saving Potential
EnergyConsumption
18%
€19657
Leakage Rate
1 2 3 4 5 6 7 8 9 100
2
4
6
8m³/min
HOLE SIZE (mm )
@7.0 bar g
£1 Coin(size reference)
1mm (0.07m³/min)
2mm (0.29m³/min)
3mm (0.66m³/min)
5mm (1.87m³/min)
10mm (7.31m³/min)
EnergyConsumption
Even after corrective action, a survey of 47 typical UK industrial sites found
that the average compressed air leakage rate was 18% of total demand
Energy Consumption - Leakage
6.8%
€7426
EnergyConsumption
6 Bar
3 Bar
Atmosphericpressure
The higher the pressure, the more air that will escape through a
given-size hole !9 Bar
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
1 2 3 4 5 6 7 8 9 10
m³/min
bar g
3mm
Energy Consumption – Drain Valves
1.0%
€1091
Cost of Condensate Removal8 x 3mm Condensate Drain Values
@7.0 bar g
£1 Coin(size reference)
Typical Solenoid Valve:
orifice dia. 3mmopen time 5 secondsclosed time 55 seconds
1mm (0.07m³/min)
2mm (0.29m³/min)Example Case Study
8 x 0.66m³/min = 5.25m³/min8 x 3.2kW = 25.6kW5 sec’s/min = 730hrs
€0.0586 x 730hrs x 25.6kW = €1091assumes 4.9kW/m³/min
3mm (0.66m³/min)
5mm (1.87m³/min)
10mm (7.31m³/min)
Energy Consumption – Filters (X2)
Minimum savings through filter optimisation €207.48
Tests indicate that average energy savings of 10.4% can be made by improving compressor
efficiency
Generation
Even after corrective action, a survey of 47 typical UK industrial sites found that the
average compressed air leakage rate was 18% of total demand
Leakage
Treatment
After improvements had been carried out, average energy savings of approximately 35% were
achieved across the ten sites surveyed
Installation of efficiency analysing equipment and knowledge based analysis of system:
EfficiencyConsumptionOutputFlowPressureQualityDistribution
To generate a report of:
• Financial• Environmental
Overall compressed air system efficiency :
To recommend and implement improvements where necessary
Reduced energy costs associatedwith compressed air
Improved system monitoring,diagnostics and responsiveness
Payback of investment in 12 months
The supply and installation of EnergAir products for monitoring & optimisation of compressed air systems providing energy cost reductions associated with system operation
Compressed Air Services Provider
12
910
1112
34
56
SEQ
ALARM
78
COMP
ALARM
EnergAir Hosting Service
On-Site PC Visualisation
Remote PCVisualisation
Energy andAlarm Reports
GSM-SMSAlarm Messages
Energy andAlarm Monitoring
CompressedAir System
EnergAir offer a support & training consultancy for the technical diagnostics associated with compressed air.
Consider your needs for compressed air
ProcessPressureQualityPower / Capacity
Breathing Suit ApplicationCase Study ( client name withheld )
Pre Filter
Post Filter
CarbonFilter
Fine Dust Filter
Suit Filter
22kW AirCompressor
AirReceiver
RefrigerantAir Dryer
DesiccantAir Dryer
BreathingSuit
108psi (7.5bar)bar
01
2
34
5 6 78
9
10
1112 7psi (0.5bar)
bar0
1
2
34
5 6 78
9
10
1112
Continually monitor the performance of your compressed air system
Your controller should be capable of continuously monitoring:
PowerPressureEfficiency
Onload
Offload
Onload 99%
Offload 1%
90kW
90kW
90kW
90kW
90kW
450kW available294kW/hr average consumption
259kW/hr average consumptionAnnual Saving = 35kW x 6000hrs
75kWVARIABLE
SPEED
30kW
90kW
90kW
90kW
No longer required - Standby
only
SMARTSEQUENCER
7.0
7.3
6.7
7.0
7.3
6.7
Two units required renewal
Before After
NIKO – BelgiumCase Study
End User Saving
€12301k / annum@€0.0586/kWh
For more information on how EnergAir can help your business please contact us
EnergAir Solutions LtdVictoria HouseDesborough StreetHigh WycombeBucks. HP11 2NF
Tel: +44 (0)1494 601155 fax: +44 (0)1494 601001email: sales@energair.co.uk web: www.energair.co.uk