Air Compressor CalculatorAir Compressor OptimizationLike all electro-mechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak efficiency and minimize unscheduled downtime. Inadequate maintenance can increase energy consumption via lower compression efficiency, air leakage, or pressure variability. It also can lead to high operating temperatures, poor moisture control, excessive contamination, and unsafe working environments. Most issues are minor and can be corrected with simple adjustments, cleaning, part replacement, or elimination of adverse conditions.

This tool calculates the energy savings associated with making minor changes to your air compressor system. Each tab calculates the energy savings associated with one of the following changes: Use outside air for air compressor intake Reduce compressor air pressure Repair compressed air leaks Use synthetic lubricant in compressors Recover waste heat from air compressor and use it to heat the plant in the winter Use vortex nozzle for cleaningEnter the data specific to your compressor in the section labeled Compressor Data. These inputs are shared by the six tabs below this section. Each tab requires additional inputs specific to the changes listed above. The cumulative savings for implementing all the changes is calculated at the bottom of the tool.Air Compressor Optimization CalculatorFor Calculationsannual energy0General Inputsmaximum pressure1Number of CompressorsUtilization Factorcurrent pressure1Horse PowerN Value1.25factor0.22856Efficiency91.5%Current Operating PressurepsigLoad Factor0.84Maximum Rated PressurepsigCO2 conversion1.341Operating HourshrsAtmosphere Pressure14.7psigCost of Electricity$/kWhDemand Cost$/kWh/moN valueSelect a Value11.25Current Energy Consumption0.0kWh2Additional Resources The US DOE Energy Management Portal: https://save-energy-now.org The US DOE Compressed Air site: http://www1.eere.energy.gov/industry/bestpractices/compressed_air.html The US DOE Compressed Air Tip Sheets: http://www1.eere.energy.gov/industry/bestpractices/tip_sheets_compressed_air.html The Compressed Air Challenge: http://www.compressedairchallenge.org/AcknowledgementThis tool was created by the West Virginia University Industrial Assessment Center. For more information about the WVU Industrial Assessment Center, visit their website www2.cemr.wvu.edu/~wwwiac/.

If unknown, use a default value of 91.5%If unkown use a default value of 0.84If unkown, use a default value of 0.08If unknown, use a default value of 14.7 psig.Compression factor based on type of compressor and polytropic efficiency. Use the following list to determine the N-value for your system.N = 1.25 for screw compressors with polytropic efficiency of 80%N = 1 for reciprocating compressor with single stageN = 2 for reciprocating compressor with double stage

Reduce Air PressureReduce Air PressureAir TemperaturesCurrent Discharge PressurepsigProposed Discharge PressurepsigImplementation DetailsLabor Hours for Pressure AdjustmentLabor Rate$/hrannual energy0current pressure1Savingsfactor0.22856Annual Energy Savings0.0kWhproposed pressure1Demand Savings0.0kWAnnual Energy Cost Savings$0.0ratio0Annual Demand Cost Savings$0.0Total Annual Cost Savings$0.0CO2 Savings0.0LbsImplementation CostTotal Cost of Implementation$0.0Current Energy Consumption0.0kWh

Outside AirOutside AirAir TemperaturesCurrent Average Intake TemperatureFAverage Outdoor Temperature51FImplementation DetailsTotal Feet of DuctftNumber of ElbowsCost of Duct$/ftCost of 1 Elbow$Labor HourshrsLabor Rate$/hrSavingsAnnual Energy Savings0.0kWhDemand Savings0.0kWAnnual Energy Cost Savings$0.0Annual Demand Cost Savings$0.0Total Annual Cost Savings$0.0CO2 Savings0.0LbsImplementation CostTotal Cost of Implementation$0.0Current Energy Consumption0.0kWh

If unkown, use a default value of 51 degrees F.

Synthetic LubricantsSynthetic LubricantsImplementation DetailsCost Difference per Gallon$Gallons RequiredgallonsSavingsAnnual Energy Savings0.0kWhDemand Savings0.0kWAnnual Energy Cost Savings$0.0Annual Demand Cost Savings$0.0Total Annual Cost Savings$0.0CO2 Savings0.0LbsImplementation CostTotal Cost of Implementation$0.0Current Energy Consumption0.0kWh

Waste HeatWaste HeatWaste HeatCost of Fuel$/MMBtuNumber of Months Plant Required Space HeatingSavingsAnnual Energy Savings0.0kWhAnnual Energy Savings0.0MMBtuTotal Annual Cost Savings$0.0CO2 Savings0.0LbsCurrent Energy Consumption0.0kWh

Vortext NozzlesVortex NozzleVortex NozzleNumber of Vortex NozzlesCompressed Air Usage FactorSCFM from NozzleOperating Period of Nozzlemin/dayUsage Factor of NozzleFor CalculationsImplementation DetailsHours per year0Cost per Nozzle$Power consumed0Labor Time per NozzlehrsLabor Rate$/hrSavingsAnnual Energy Savings0.0kWhDemand Savings0.0kWAnnual Energy Cost Savings$0.0Annual Demand Cost Savings$0.0Total Annual Cost Savings$0.0CO2 Savings0.0LbsImplementation CostTotal Cost of Implementation$0.0Current Energy Consumption0.0kWh

If unknown, use a default value of 0.1If unkown, use a default value of 1.

Air LeaksAir LeaksAir TemperaturesLine Pressure at the LeakpsigAverage Line TemperatureFCurrent Average Intake TemperatureFNumber of Air LeaksAverage Size (Diameter)inImplementation DetailsTotal Feet of DuctftNumber of Leaks per yearCost to Fix a Leak$Labor Hours to Fix a LeakhrsFor CalculationsLabor Rate$/hrefficiencySavingsAnnual Energy Savings0.0kWhline pressure1Demand Savings0.0kWleak volume0Annual Energy Cost Savings$0.0power loss0Annual Demand Cost Savings$0.0Total Annual Cost Savings$0.0CO2 Savings0.0LbsImplementation CostTotal Cost of Implementation$0.0Current Energy Consumption0kWh

InstructionsInstructions for using the Air Compressor Tool1Enter the general inputs on the first tab. All fields must be filled in.2Enter input values into the 6 tabs (Outside Air, Reduce Air Pressure, Synthetic Lubricants, Waste Heat, Vortex Nozzles, and Air Leaks). All of the tabs do not need to be filled in.3Results will appear in the grey section of each tab.KeyUtilization FactorsThe maximum demand of a system divided by its rated capacity.Load FactorsThe average power divided by the peak power over a period of time.EfficiencyEnter the efficiency of your system as a decimal value between 0 and 1.Maximum Rated PressureThe maximum pressure at which the manufacturer determines it is safe to operate the nozzle.Current Operating PressureThe pressure the compressed air system is currently operating at.Atmospheric PressureIf unknown, use the default value of 14.7 psig.N ValueCompression factor based on type of compressor and polytropic efficiency. Use the following list to determine the N-value for your system.N = 1.25 for screw compressors with polytropic efficiency of 80%N = 1 for reciprocating compressor with single stageN = 2 for reciprocating compressor with double stage