compressed air usage energy presentation.pdf · compressed air usage air compressor 10% of...
TRANSCRIPT
![Page 1: Compressed Air Usage energy presentation.pdf · Compressed Air Usage Air Compressor 10% of industrial electricity used to power air compressors ... average compressed air leakage](https://reader031.vdocuments.mx/reader031/viewer/2022011908/5f5688b8e8c8fb56ec1cfaec/html5/thumbnails/1.jpg)
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Compressed Air Usage
Air Compressor
10% of industrial electricity used to power air compressors
7,500 kWh€498m per annum10%
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A Typical Rotary Screw Air Compressor
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Represents by far:
The single largest cost associated with compressed air
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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
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Example case study
€21841€14 561
€109 208
AnnualCost
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Key Savings Opportunities
Optimisation of:
PressureControlLeakageFilter Elements
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Energy Savings PotentialExample Case Study
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Energy Savings PotentialExample Case Study
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Energy Consumption - Pressure
1.5%
€1 639
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Energy Consumption - Pressure
Designing and operating a system at unnecessarily high pressures will waste energy and increase running costs
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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
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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
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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!!
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PressureEnergy Consumption - Control
5.2%
€5733
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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
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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
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EnergyConsumption
18%
€19657
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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)
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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
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Energy Consumption - Leakage
6.8%
€7426
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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
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Energy Consumption – Drain Valves
1.0%
€1091
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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)
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Energy Consumption – Filters (X2)
Minimum savings through filter optimisation €207.48
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Tests indicate that average energy savings of 10.4% can be made by improving compressor
efficiency
Generation
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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
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Treatment
After improvements had been carried out, average energy savings of approximately 35% were
achieved across the ten sites surveyed
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Installation of efficiency analysing equipment and knowledge based analysis of system:
EfficiencyConsumptionOutputFlowPressureQualityDistribution
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To generate a report of:
• Financial• Environmental
Overall compressed air system efficiency :
To recommend and implement improvements where necessary
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Reduced energy costs associatedwith compressed air
Improved system monitoring,diagnostics and responsiveness
Payback of investment in 12 months
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The supply and installation of EnergAir products for monitoring & optimisation of compressed air systems providing energy cost reductions associated with system operation
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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
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EnergAir offer a support & training consultancy for the technical diagnostics associated with compressed air.
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Consider your needs for compressed air
ProcessPressureQualityPower / Capacity
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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
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Continually monitor the performance of your compressed air system
Your controller should be capable of continuously monitoring:
PowerPressureEfficiency
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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
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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: [email protected] web: www.energair.co.uk