Professional Documents
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Technology Overview
Compressed air
Introducing energy saving opportunities for business
Contents
Compressed air in industry Air compressors technology overview
Types of air compressor 02
04 05 06 06 08 10 12 14 15 16 18 20 21 22 23
Compressed air
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Reducing energy use makes perfect business sense; it saves money, enhances corporate reputation and helps everyone in the ght against climate change. The Carbon Trust provides simple, effective advice to help businesses take action to reduce carbon emissions, and the simplest way to do this is to use energy more efciently. This technology overview introduces the energy saving opportunities for compressed air systems and demonstrates how simple actions save energy, cut costs and increase prot margins.
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Technology Overview
Compressed air
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The process of compressing air can be wasteful. Of the total energy supplied to a compressor, as little as 810% may be converted into useful energy that can do work at the point of use. This makes it a very expensive form of energy. Despite the high cost of production, many systems waste up to 30% of the compressed air through leaks, poor maintenance, misapplication and poor control. These gures demonstrate the cost of running a compressed air system and the value of minimising wastage. This overview of compressed air demonstrates how action can be taken to reduce waste and save energy and money.
Figure 1 (below) shows that, over a ten-year life of a compressor, the cost of energy to run the system far outweighs the capital investment. It also shows that maintenance accounts for 7% of the total costs, yet this is a crucial activity for maximising the energy efciency of any compressor. Figure 1 Compressor costs over a ten-year life
Installation cost 2% Maintenance cost 7%
fact:
Annually, UK industry uses over 20T Wh of electricity to compress air equivalent to the output of four power stations and over 8.1 million tonnes of CO2 emitted to the atmosphere.
Energy cost 73%
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Technology Overview
5. Dryer 4. Filter
Note: most cases will incorporate an integral oil cooler and aftercooler
Some businesses will have portable units, which have all the main components of a compressed air system. They are usually used for small-scale applications or when a mobile source is needed.
Compressor
Ring main Drain line system Branch line Main trunk line
Oil/water separator User process (large intermittent demand for compressed air)
Compressed air
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Technology Overview
Train staff
Make sure staff members are aware of the costs associated with compressed air. Undertake a training programme to show how staff can contribute to saving energy by discussing the above issues/policy with them. When doing so, it is important to involve staff and give them the opportunity to provide feedback failure to do this could result in them reverting to their previous way of working. Companies that make the biggest savings have trained staff to understand the cost of producing compressed air, the interdependency of the components of a compressed air system and the importance of saving energy.
Safety rst!
Check that the person carrying out changes to a compressed air system has the relevant skills and always ask for expert help if in any doubt.
fact:
Even when idling, compressors can consume between 2070% of their full load power.
Compressed air
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Switch off
Watch what happens to air-consuming equipment when there is no production, for example, during a tea break or job change. Is equipment left working when not required? Instigate switch-off routines and include them in the compressed air usage policy. Consider whether it is appropriate to do this for each process and plan when they will be implemented. This process could even be automated using time-operated solenoid valves or interlocks, which allow a compressed air line to operate only if another piece of equipment is already running. Another, more complex, option would be to use sensors that detect when a part is present and some form of control electronics to operate compressed air valves as and when required. These systems are easy to install and, usually, more than pay for their cost in energy savings.
top tip:
air are Waste and misuse of compressed e usually thes ng misi Mini . stry common in indu no-cost and offers the greatest potential for em. syst cal typi a in low-cost savings
Air is free but compressed air is not. Use alternatives where possible.
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Technology Overview
Leak reduction
All compressed air systems have leaks, even new ones. Reducing air leaks is the single most important energy saving action for most sites.
It is impossible to calculate an average leakage rate but a target for a well-maintained system should be around 10% of air generated lost to leakage. The leak rate on an unmanaged compressed air system can be as much as 4050% of the generated output and in certain applications even higher gures have been measured. It is worth mentioning here that the amount of compressed air lost to leakage is reduced at a lower system pressure (see section on Generation and control on page 10 and Articial demand in the glossary). When they occur upstream of pressure regulators, leaks are effectively unregulated air demands and increasing system pressure causes every such leak in the system to pass more air. The sources of leakage are numerous, but the most frequent causes are: Manual condensate drain valves left open Shut-off valves left open Leaking hoses and couplings Leaking pipes, anges and pipe joints Leaking pressure regulators Air-using equipment left in operation when not needed. Compressed air leaks represent a safety problem due to factors such as blowing air and noise. Furthermore, they have the potential to interrupt production through equipment failure and lead to additional costs through: Fluctuating system pressure. This can cause air tools and other air-operated equipment to function less efciently potentially affecting or stalling production. It can also bring about quality issues. For example, a torque wrench used in production may have been calibrated at a 600kPa(g) (6bar(g)) working pressure. If high leakage losses cause pressure reductions in the area, the torque wrench will not tighten correctly Reduced service life and increased maintenance of equipment due to unnecessary compressor cycling and running time Excess compressor capacity required on line. When the cost of all leaks and wastage due to inadequate maintenance is calculated, the outlay for purchase of suitable detection equipment and replacement parts is almost always justied.
top tip:
Have an ongoing test and repair programme for leaks. Note that leaks reappear and a 3m m hole could cost as much as 2, 200/year in wasted energy.
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Where possible, avoid using compressed air for drying applications. In the food canning industry, for example, air knives are used to blow excess water off cans at great expense in terms of the energy required to compress the air in the rst place. For every 100 units of electricity that go into the compressor, as few as 10 units of compressed air could be available to use, in which case the air leaving the compressor would typically cost the equivalent of over 50p/kWh1. Again, alternative solutions such as blowers or even using the rejected heat from the plant compressor should be considered.
fact:
one 3mm hole in Finding and repairing can save more a compressed air system cover the cost than enough money to c leak detector. of buying an ultrasoni
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Technology Overview
fact:
You can save 1% of energy use by reducing the air intake temperature by 4o C.
Compressed air
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fact:
kPa(g) pressor operating at 700 For a typical screw com re, a ssu Pa (0.5bar) drop in pre (7bar(g)), for every 50k e 3-4% less energy. compressor will requir
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Technology Overview
Air treatment
During the process of compressing and distributing the air, impurities inevitably nd their way into the system. These reduce air quality and can signicantly affect the system efciency, including the performance and life of the end-use equipment. Therefore, in most compressed air systems, the air will require some form of treatment to ensure that it is of a suitable quality. Air treatment is energy intensive and air should only be treated to meet the minimum levels required. Energy is often wasted due to poor installation and maintenance of treatment equipment, and because the system has not been adjusted following a change in demand. Treatment systems and components are normally specied in accordance with ISO 8573 which provides classication in terms of oil, particulate and moisture in the system. Dryer. This equipment allows the air to be dried to a specic humidity. Dryers can vary greatly in design, ranging from desiccant dryers that are used to achieve a very low dew point (the temperature at which water will reform) of between 20 and 70C, to refrigerated dryers by far the most common type. Refrigerated dryers are normally fairly energy efcient and have a typical dew point of 3C. Adjustable dew points should be considered where the air does not need to be dried to such a high quality. The high level of treatment provided by desiccant dryers means that they tend to use more energy. After-lters. These lters can provide further removal of particulates for critical applications as well as oil and oil odours if required. They are typically of the nest mesh size. Condensate drains. These are used to remove condensate from the system at points where water collects (typically, receivers, dryers, lters, pipe drain points) and can be another source of signicant energy wastage. Commonly, condensate is removed using a timed solenoid drain that uses compressed air to exhaust the condensate to a condensate management system at a predetermined interval for a set period of time. Typically, the valve opens for 3 seconds every 1530 minutes. However, to operate correctly, these drains require constant adjustment to take account of changing ambient conditions and/or system load. When set incorrectly, they discharge signicant amounts of air or fail to remove all of the condensate resulting in downstream contamination. They can also be prone to sticking in either the open or closed position should the vent orice become damaged or contaminated. They can also lead to corrosion in the system, causing air leaks as well as delivering poor quality air at the point of use. A more energy efcient option is to use no-loss type electronic condensate drains that use full bore to discharge rather than a small orice. These do not waste compressed air, as this type of drain usually works by sensing an upper and lower liquid level. When the upper level is reached the valve opens and uses compressed air to force out the condensate. When the liquid reaches the lower sensor the air supply is shut off thus preventing compressed air from escaping and being wasted.
fact:
es ssor can generate 20 litr A single 30kW compre the of n tio nsa de m the con of water in 8 hours fro on process. ssi pre com air during the
Compressed air
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During energy efciency surveys, treatment systems can often be overlooked as they are frequently perceived to be necessary and not changeable. However, a 100kPa (1bar) pressure differential across a dryer/lter can be wasting as much as 3% of the total air-generation costs.
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Technology Overview
Compressed air
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Maintenance
There are two different approaches to maintenance: planned preventive maintenance (PPM) and breakdown maintenance. PPM is carried out regardless of whether a machine has broken down. This is essential for all critical compressed air systems to achieve long-term reliability as well as energy efcient operation. Breakdown maintenance is reactive and should be regarded only as a temporary quick-x solution. PPM should always be the preferred method of looking after compressed air assets. Predictive maintenance can pay off for larger systems particularly. Special equipment can be used to anticipate when problems start to occur. For example, use: Vibration analysis, where rotational equipment is analysed for noise and vibration Oil analysis, which can identify friction issues or contamination issues Thermographic surveys, which can identify overheating issues as well as electrical faults. Further details can be found in the Carbon Trusts publication Identifying energy savings with thermal imaging (CTG003). A compressed air supplier will be able to advise on all of the above predictive maintenance techniques. All of these methods can help to identify problems before they become failures and point to areas of increased energy consumption. Note that compressors cannot be run for ever on just basic servicing, oil/lter changes and so forth, and the maintenance schedule should include major overhauls such as the replacement of screw elements in accordance with the manufacturers recommendations. For an oil-injected rotary screw compressor this is likely to be around 25,000 hours. The compressor will continue to operate after this but efciency and performance will deteriorate without ongoing maintenance.
Schedule maintenance
Check equipment maintenance requirements against the actual maintenance carried out. An appropriate maintenance schedule should be devised in accordance with the manufacturers requirements. Alternatively, use a reputable maintenance contractor manufacturers should be able to advise on this.
fact:
r 30 0 typical Tests carried out on ove t energy savings tha d compressors showe through low-cost of 10% can be achieved s. So, in addition maintenance activitie y, maintenance ilit to improving reliab d money. an y can also save energ
To order a copy of Identifying energy savings with thermal imaging (CTG003) and other relevant publications, contact the Carbon Trust (details can be found inside the back cover).
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Technology Overview
Monitoring
Without a method for monitoring consumption, energy waste is likely to be ongoing and minimising costs will be more difcult to achieve.
A good monitoring system will help identify how much energy a system uses and where it is being used. It will also help in setting energy reduction targets and identifying where improvements can be made. Higher than expected levels of energy consumption can point to: Poor maintenance Faulty equipment Increased leakage Misuse of compressed air System pressure that is too high Compressors not being turned off. Once energy saving measures have been implemented, then monitoring will also demonstrate the savings directly attributable to the energy saving actions.
Compressed air
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Airflow (m3/week)
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Technology Overview
To order a copy of Variable speed drives technology guide (CTG006), contact the Carbon Trust (details can be found inside the back cover).
Compressed air
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Technology Overview
Legislative requirements
There are a number of legal requirements to consider when dealing with compressed air. The main requirements are outlined in Pressure Systems Safety Regulations 2000 available from the Ofce of Public Sector Information (www.opsi.gov.uk). Here are just a few considerations: A Written scheme of examination must be prepared and be certied by a competent person, which identies how the system shall, in future, be examined There should be a regular examination of the system by a competent examiner to ensure that it continues to comply with the regulations Comprehensive operating instructions including start-up and shutdown procedures should be supplied to all operators Pressure vessels and, in particular, air receivers should be clearly marked. Other regulations relate to environmental legislation and cover areas such as condensate disposal. Oil-laden condensate must be treated as a hazardous waste and cannot be discharged to normal surface or foul drains. Advice on all applicable regulations is available from the British Compressed Air Society (BCAS). Visit their website at www.bcas.org.uk for more details.
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Glossary
Absolute pressure Aftercooler Articial demand Bar/bar(g) The pressure measured from a baseline of a perfect vacuum. Denoted by (a) after the unit of pressure. Absolute pressure = Gauge pressure + Atmospheric pressure. A heat exchanger that reduces the temperature of the air after compression before it enters the system. The difference between the airow of the system at its optimum operating pressure and the ow being consumed at the actual pressure applied to the system. A unit of pressure commonly used in industry, which is approximately equal to atmospheric pressure. However, the SI unit for pressure is the Pascal (Pa). 1 bar is equal to 100,000 Pascals (100kPa). When referring to the pressure indicated by a system gauge (that is gauge pressure), it will often be written as bar(g). See gauge pressure below. Water/oil formed in a compressed air system from water vapour due to a decrease in air temperature and/or an increase in pressure. The temperature at which air, at a given pressure, is fully saturated. Water vapour will condense if there is a further drop in temperature or increase in pressure. In a duel tower drying system, the time a dryer takes to cycle between regenerating its wet desiccant bed and drying the compressed air. A portion of dry, full line pressure, compressed air taken from the drying side tower of a dual tower desiccant dryer system. Expanded to a very low pressure and passed across the wet desiccant to strip the moisture in the desiccant. The actual ow delivered by a compressor at the stated intake (fad) temperature and pressure. Fad is expressed in litres per second, cubic metres per minute or hour or cubic feet per minute. The pressure measured from a baseline of atmospheric pressure. Denoted by (g) after the unit of pressure. Gauge pressure = Absolute pressure Atmospheric pressure. Equal to 1,000Pa (see Pascal). The compressor is running and consuming power but is not delivering air. An air compressor into which oil is injected to lubricate and remove heat. The compressor is producing air, either at part load or full load. Self-contained unit consisting of a compressor, a prime mover and various accessories (for example, lters and coolers). The SI unit for pressure. When referring to the pressure indicated by a system gauge (that is gauge pressure), it will often be written as kPa(g). See gauge pressure above. The drop in pressure between any two specied points in a system.
Free air delivered Gauge pressure kPa Off-load Oil-injected On-load Packaged air systems Pascal (Pa) Pressure drop
Pressure regulator A device that reduces the incoming pressure to a lower level and maintains it irrespective of changes in inlet pressure and outlet ow rate. Prime mover Run-on timer SI units A machine used to drive a compressor (for example, an electric motor or engine). A control that switches off the prime mover when the compressor has been off-load for a specied period of time. System of coherent metric units (Systme International dUnits) proposed for international acceptance in 1960. There are numerous derived units and scales of decimal multiples and sub multiples, all with agreed symbols. Term referring to the capability of a system to store a buffer volume of air. Effective useful storage is that which is sufcient to smooth out variations in pressure and provide a reserve to meet high demands.
Useful storage
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Technology Overview
Appendix
Leakage measurement test
With both the following methods, it is assumed that the compressed air system is operating after normal plant operating hours, that the air being delivered is supplying only leaks and that there are no normal production or process requirements. Different sections of the distribution network can be tested if well-sealing valves can be used to isolate different branches.
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Next steps
Assess the condition and operation of the system, and identify where efciency can be improved. Considerable savings can be made by taking action in-house. However, specialist support from a contractor or consultant may be needed for others. Below is a step-by-step approach to consider.
Step 1. Understand the system
Look at the system and identify where all the components are situated. Check the condition and operation of the key components as described in this document. If possible, monitor the power consumption over, say, one week to gain a baseline against which any improvements to energy efciency can be measured.
Step 5. Seek specialist help Step 2. Understand how the system is used
Examine the way in which the system is used. Think about issues such as pressure settings, air intakes, misuse and alternatives. Discuss the more complex options with a specialist contractor/consultant or contact the Carbon Trust. If you need to identify a suitable specialist, contact the British Compressed Air Society (BCAS).
Related publications
The following publications are available from the Carbon Trust: Sector overviews Chemicals (CTV012) Food and drink processing (CTV004) High temperature industry (CTV011) Manufacturing (CTV015) Technology overviews Motors and drives (CTV016) Technology guides Thermal imaging (CTG003) Variable speed drives (CTG006) DVDs Motors & drives and Compressed air (CTX604)
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Technology Overview
Notes
www.carbontrust.co.uk/energy
All of our publications are available to order or download from the Carbon Trust website at www.carbontrust.co.uk/energy. The site provides a range of information suited to every level of experience including top tips, action plans, forthcoming events and details of the range of services available from the Carbon Trust.
The Carbon Trust works with business and the public sector to cut carbon emissions and capture the commercial potential of low-carbon technologies. An independent company set up by the Government to help the UK meet its climate change obligations through business-focused solutions to carbon emission reduction, the Carbon Trust is grant funded by the Department for Environment, Food and Rural Affairs, the Department of Trade and Industry, the Scottish Executive, the Welsh Assembly Government and Invest Northern Ireland. Whilst reasonable steps have been taken to ensure that the information contained within this publication is correct, the authors, the Carbon Trust, its agents, contractors and sub-contractors give no warranty and make no representation as to its accuracy and accept no liability for any errors or omissions. Any trademarks, service marks or logos used in this publication, and copyright in it, are the property of the Carbon Trust. Nothing in this publication shall be construed as granting any licence or right to use or reproduce any of the trademarks, service marks, logos, copyright or any proprietary information in any way without the Carbon Trusts prior written permission. The Carbon Trust enforces infringements of its intellectual property rights to the full extent permitted by law. The Carbon Trust is a company limited by guarantee and registered in England and Wales under Company number 4190230 with its Registered Ofce at: 8th Floor, 3 Clements Inn, London WC2A 2AZ. Printed on paper containing a minimum of 75% de-inked post-consumer waste. Published in the UK: March 2007. Queens Printer and Controller of HMSO. CTV017