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Why Compressed Air Is So Expensive Why Compressed Air Is So Expensive
and
What To Do About It
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PresenterPresenterPresenterPresenterRon Marshall
• Technical Officer – Manitoba Hydro
• 37 year Employee
• 19 years Technical CA Support – POP
• CAC Instructor
• CAC Marketing Chairman
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Coming UpComing UpComing UpComing Up
• Why compressed air is so expensive
• Three secrets of compressed air efficiency
• The effects of system pressure
• Improving how CA is producedp g p
• Transmitting CA more efficiently
• Reducing waste and misuseg
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Cost of Compressed AirCost of Compressed AirCost of Compressed AirCost of Compressed Air• Typical air cooled compressor Specific Power• Typical air cooled compressor Specific Power
• 20 to 21 kW/100 cfm at 125 psi
18 to 19 kW/100 cfm at 100 psi• 18 to 19 kW/100 cfm at 100 psi
• For two shift/ 5 day $7,900 per 100 cfm
24 7 ti $16 640 100 f• 24 x 7 operation $16,640 per 100 cfm
• 10 cents per kWh, 100% loaded
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Poor Production Poor Production EfficiencyEfficiency
Every 7.5 hp power input to the
compressor results in only 1 hp
output at the compressed air
end use!
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Example Air MotorExample Air Motor
Compressed Air Motor• 30 cfm input = 1 HP output• 5.7 kW input = 0.8 kW output
$2,330 (compressed air) vs. $390 (electric)
7 times more costly
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Why Use Compressed Air?Why Use Compressed Air?Why Use Compressed Air?Why Use Compressed Air?Compressed air systems are used in almost every sector of the
econom and there are tho sands of different ses foreconomy, and there are thousands of different uses for compressed air. Air operated equipment:
• Tends to be lighter and more maneuverable than electricg• Deliver smooth power and are not damaged by overloading• Have the capability of infinitely variable speed and torque
t lcontrol• Are safer because they do not have the potential hazards of
electrical devices, particularly when water and gases are presentp y g p
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Why Use Compressed Air?Why Use Compressed Air?Why Use Compressed Air?Why Use Compressed Air?There are many applications where compressed air is the
best overall solution
• Whether its pneumatic tools, packaging, automation equipment, conveyors, controls systems, and others
• When compressed air is needed to make a product, it h ld b d i l d t th high t f ki g th should be used wisely due to the high cost of making the
compressed air
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Not real world conditionsNot real world conditionsNot real world conditionsNot real world conditions
Previous calculation assumes lossless system
Real systems have:Real systems have:
• Leaks, artificial demand
• Pressure lossesPressure losses
• Inefficient compressed air production
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Real System have lossesReal System have lossesReal System have lossesReal System have losses
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Leaks Add WasteLeaks Add WasteLeaks Add WasteLeaks Add WasteTypical leak level 15 to
30%
Leaked air never
Source: Carbon Trust
makes it to the end use
Source: Carbon Trust
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Pressure DropPressure DropPressure DropPressure Drop
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Pressure DropPressure DropPressure DropPressure Drop
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Pressure Pressure –– Rule of ThumbRule of ThumbPressure Pressure Rule of ThumbRule of Thumb
• Every 2 psi increase in discharge pressure results in 1 percent more energy p gyconsumption
(Valid around 100 psi)
• Makes real world compressed air cost • Makes real world compressed air cost more than the perfect system
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Compressor EfficiencyCompressor EfficiencyCompressor EfficiencyCompressor Efficiency
At full load
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System Average LoadingSystem Average LoadingSystem Average LoadingSystem Average Loading
25 to 40%25 to 40%Study by Manitoba Hydro
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Screw Compressor CharacteristicsScrew Compressor Characteristicspp
40% fl 82% kW 2 th t40% flow = 82% kW = 2 x the cost
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Additional CostsAdditional CostsAdditional CostsAdditional Costs
• Air dryers
• Drains and condensate disposalDrains and condensate disposal
• Cooling costs (fans, water, water treatment)
• MaintenanceMaintenance
• Equipment replacement
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Real World EfficiencyReal World EfficiencyReal World EfficiencyReal World EfficiencyReal world examplePerfect compressor Real world example
• Inefficient part load
• 30% leaks
Perfect compressor
• No part loading
• No pressure drop • 30% leaks
• 30 psi pressure drop
25 hp in = 1 hp out
• No pressure drop
• No waste
7 5 hp in = 1 hp out 25 hp in = 1 hp out7.5 hp in = 1 hp out
This is why compressed air is so expensives s y co p essed a s so e pe s e
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Things can improveThings can improveThings can improveThings can improve
Many of these additional costs are due to:
• Poorly operating equipment due to improper system Poorly operating equipment due to improper system design
• Poor maintenance practicesp
• Use of production equipment with poor energy characteristics at part loads
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Secrets to CA EfficiencySecrets to CA EfficiencySecrets to CA EfficiencySecrets to CA Efficiency
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Secrets to CA EfficiencySecrets to CA EfficiencySecrets to CA EfficiencySecrets to CA Efficiency
• Produce compressed air more efficiently
• Use less compressed air
• Use the heat of compression for something useful
Source: ASME EA-4
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Pressure EffectsPressure EffectsPressure EffectsPressure Effects1/64’’ 1/32’’ 1/16’’ 1/8’’ 1/4’’ 3/8’’1/64’’ 1/32’’ 1/16’’ 1/8’’ 1/4’’ 3/8’’
70 psi .300 1.20 4.79 19.2 76.7 17380 i 335 1 34 5 36 21 4 85 7 19380 psi .335 1.34 5.36 21.4 85.7 19390 psi .370 1.48 5.92 23.8 94.8 213
100 psi .406 1.62 6.49 26.0 104 234125 psi .494 1.98 7.90 31.6 126 284
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Pressure EffectsPressure EffectsPressure EffectsPressure Effects1/64’’ 1/32’’ 1/16’’ 1/8’’ 1/4’’ 3/8’’1/64’’ 1/32’’ 1/16’’ 1/8’’ 1/4’’ 3/8’’
70 psi .300 1.20 4.79 19.2 76.7 17380 i 335 1 34 5 36 21 4 85 7 19380 psi .335 1.34 5.36 21.4 85.7 19390 psi .370 1.48 5.92 23.8 94.8 213
100 psi .406 1.62 6.49 26.0 104 234125 psi .494 1.98 7.90 31.6 126 284
10 psi = 10% more flow
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Pressure EffectsPressure EffectsPressure EffectsPressure Effects• Every 2 psi increase in discharge psi • Every 2 psi increase in discharge psi
increases power by 1%
• Every 1 psi in pressure increases • Every 1 psi in pressure increases unregulated flow by 1%
• This increased flow further increases the This increased flow further increases the compressor power
• Power increase depends on control modep
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Improving the Supply SideImproving the Supply SideImproving the Supply SideImproving the Supply Side• More efficient compressor and dryer controlMore efficient compressor and dryer control
o Adding storage
o Operating in a different control mode
• Lower discharge pressure
• More efficient compressors and dryers
• Improved maintenance
• Improved ambient conditions
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Improving the Supply SideImproving the Supply SideImproving the Supply SideImproving the Supply SideAutomobile analogyAutomobile analogy
• Modulation
• Load/Unload• Load/Unload
• Start/Stop
• VSD• VSD
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Control ImprovementsControl ImprovementsControl ImprovementsControl Improvements• Adding storage
100
70
80
90
40
50
60
Perc
ent F
L kW
Modulating
Load/Unload Small Tank
Load/Unload Big Tank
0
10
20
30
VSD or Start/Stop
0 10 20 30 40 50 60 70 80 90 100
Percent Output
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Control ImprovementsControl ImprovementsControl ImprovementsControl Improvements• Control Change
100
70
80
90
40
50
60
Perc
ent F
L kW
Modulating
Load/Unload Small Tank
Load/Unload Big Tank
0
10
20
30
VSD or Start/Stop
0 10 20 30 40 50 60 70 80 90 100
Percent Output
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Control ImprovementsControl ImprovementsControl ImprovementsControl Improvements• Sequencing compressor controls
• Cycling refrigerated air dryers
• Dew point controlled desiccant dryers
• Reduced purge desiccant dryers (externally heated or blower purge)
• Controls that turn off production equipment when not required (nights, weekends)
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Maintenance and AmbientMaintenance and AmbientMaintenance and AmbientMaintenance and Ambient• Clogged filters decreases compressor efficiencyClogged filters decreases compressor efficiency
• Clogged coolers causes high temperatures and water problems forcing more compressed air drainageproblems forcing more compressed air drainage
• Cooler compressors produce more efficiently
• Negative room pressures reduce efficiencyNegative room pressures reduce efficiency
• Heat from compressor rooms can be directed where needed
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Transmission LossesTransmission LossesTransmission LossesTransmission Losses
Distribution Pipes
Local Components
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Transmission LossesTransmission LossesTransmission LossesTransmission Losses10.0
7.5
d
Cutting the flow in half
reduces dp by 75%
2.5
5.0Psid reduces dp by 75%
0.00 25 50 75 100
% Flow
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Reducing Transmission LossReducing Transmission LossReducing Transmission LossReducing Transmission Loss
• Pressure drop reduction reduces to the square of the flow • Pressure drop reduction reduces to the square of the flow reduction
• Loop piping rather than radial feeds• Loop piping rather than radial feeds
• Increase piping size
• Filters regulators lubricators sized for peak• Filters, regulators, lubricators sized for peak
• Hoses, connectors, fittings sized for peak
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Peak Peak vsvs AverageAveragePeak Peak vsvs AverageAverageExample:
A t t 2 bi f t 1 • Actuator consumes 2 cubic feet per 1 second cycle, 4 times per minute = 8 cfm average
• 2 cubic feet in one second is a peak flow rate of 120 cfm
• Components and supply lines sized for Co po e ts a d supp y es s ed oaverage would be grossly undersized
• Resulting pressure drop increases required compressor discharge pressurerequired compressor discharge pressure
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Reducing Transmission LossReducing Transmission LossReducing Transmission LossReducing Transmission Loss
Piping system and hoses DP reduction (almost like magic)
• Upgrade from 1 ½ to 2 inch pipe reduces dp by 73%• Upgrade from 1 ½ to 2 inch pipe reduces dp by 73%
• Increase 1/4 inch hose to 3/8 reduces by 88%• Decreased pressure drop allows lower compressor Decreased pressure drop allows lower compressor
discharge pressure
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Reducing the Demand SideReducing the Demand SideReducing the Demand SideReducing the Demand Side• Leakage reduction• Leakage reduction
• Inappropriate use optimization
Artificial demand elimination• Artificial demand elimination
• Abandoned use reduction
R g l t d d • Regulated end use pressure
• Proper component design
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Leakage ReductionLeakage ReductionLeakage ReductionLeakage Reduction• Find and Fix Leaks• Find and Fix Leaks
• Use ultrasonic leak detectors to find
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Inappropriate UsesInappropriate UsesInappropriate UsesInappropriate Uses• Find replace eliminate optimize• Find, replace, eliminate, optimize
• Blowing • Vacuumg
• Agitation
• Atomizing
• Transport
• Aspirationg
• Cabinet Cooling
p
• Personal Cooling
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Artificial Demand ReductionArtificial Demand ReductionArtificial Demand ReductionArtificial Demand Reduction
• Reduce the pressure• Reduce the pressure
• Regulate the main system with pressure/ flow control
Reg late end se• Regulate end use
• Flow in unregulated uses reduces 1% per psi
C d• Compressor power reduces
• May require equipment or component retrofit or redesign if one machine prevents wholesale psi reductionone machine prevents wholesale psi reduction
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Abandoned Use ReductionAbandoned Use ReductionAbandoned Use ReductionAbandoned Use Reduction
• Turn it off• Turn it off
• Install solenoid control
Train staff to sh t off• Train staff to shut off
• Turn the complete system off if no production at night and weekendsweekends
• Flow reduction = energy savings
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Lower psi = lower Lower psi = lower cfmcfmLower psi lower Lower psi lower cfmcfmExample:• Actuator consumes 2 cubic feet
per cycle at 120 psi = 8 cfm• Reduction to 90 psi consumes 6 • Reduction to 90 psi consumes 6
cfm• 22% savings22% savings• Low pressure or spring powered
retract stroke saves energy
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Low psi drop = lower Low psi drop = lower cfmcfmLow psi drop lower Low psi drop lower cfmcfm• Poorly designed y g
components cause discharge pressure increase
P i • Pressure increase causes artificial demand and higher compressor powerp p
• Properly size components for savings
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SummarySummarySummarySummary• Compressed air is expensive more expensive if wasted Compressed air is expensive, more expensive if wasted
and produced by inefficient equipment
• Secret to produce efficiently and use less. Keep the heat.Secret to produce efficiently and use less. Keep the heat.
• High pressure costs money
• Production of compressed air can be made more efficentProduction of compressed air can be made more efficent
• Reducing pressure loss in transmission saves energy
• Reducing waste and misuse lowers costsReducing waste and misuse lowers costs
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Where to Get HelpWhere to Get HelpWhere to Get HelpWhere to Get Help• Additional training from CAC
• Compressed Air Best Practices Manual
Vi it CAC b it • Visit CAC website: www.compressedairchallenge.org
o Tools
o Articles
o Training Links
o LinkedIn Discussion