Energy Conservation

in

Air Compressors & Compressed Air System

Life Cycle Cost For A Compressor

Initial Cost 5% Maintenance cost 5%

Energy Cost 90%

Confederation of Indian Industry

Air Compressors
Positive Displacement Type Centrifugal Type

Reciprocating Vertical Type (100-500 cfm) Horizontal Balance Opposed

Rotary Screw (high speed) Advantage: Intake air can also have some moisture

Radial Flow

Axial Flow

> 12000 cfm

(200-5000 cfm)

Disadvantage: Oil carry over

Confederation of Indian Industry

Single Acting, 2-Stage Reciprocating Compressor

*Filter
Motor starter Inlet filter Inter cooler After cooler

Dryer

Motor

Relief valve Trap (Drain)

Trap (Drain)

Pressure switch Receiver

Trap (Drain)

Why Inter-cooler?
Compressed air leaves at high temp. Density is lower
Volumetric h decreases

Inter-cooling reduces temperature & volume

Mass of air delivered increases

Inter-cooler generally saves 7 %

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Why After-cooler? How much is the energy savings?

Savings same as inter cooler - 7 % Higher than inter cooler Lesser than inter cooler
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Why After-Cooler? How much is the energy savings?

At higher temperature moisture carry over very high
Condensed water moves with same velocity of air
Damage to instrument valves Makes instruments sluggish

After-cooler saves energy only when air dryers are installed

Confederation of Indian Industry

Methodology for Energy Audit

Is the correct type and size of compressor being used? Is the system efficient? What is the required operating pressure? What is pressure drop between user and compressor?

Is correct type of dryer used?

Confederation of Indian Industry

Methodology for Energy Audit

Is compressor cooling water monitored?

Are auto drain valves provided?

Can compressed air be substituted? Are valves provided at the user points?

Confederation of Indian Industry

Optimal Utilisation of Compressors

Background 37 kW compressor in operation
At present loading - 30% Unloading - 70%

Power consumption
Unload - 9 kW Loading - 27 kW
Confederation of Indian Industry

Optimal Utilisation of Compressors

Action
Install 15 kW package air compressor
Saves no-load power Use existing compressor as stand-by

Rs.

Rs.

Annual Savings Investment Payback period

Confederation of Indian Industry

- Rs.59,000 - Rs.50,000 - 11 months

Optimal Utilisation of Compressors

Air requirement - 100 cfm normal running In case of yarn breakage, sudden demand of 600 cfm
Compressor Capacity : Screw type : 600 cfm

Avg. loading : 17% (during normal running)

Confederation of Indian Industry

Optimal Utilisation of Compressors

Action
Installed new air compressor of 125 cfm

capacity for normal operation

When pressure falls in receiver, screw

compressor to start automatically

Annual Savings Investment Payback period : Rs. 5.99 lakhs : Rs. 1.50 lakhs : 3 months

Confederation of Indian Industry

Capacity Test (Pumping Method)

Average Compressor Delivery = P2 - P1

. VR .

P1 = Initial pressure in receiver P2 = Final pressure in receiver P = Atmospheric pressure

VR = Volume of air in receiver

t = Time taken for charging receiver from P1 to P2
Confederation of Indian Industry

Comparison of Specific Power Consumption

Reciprocating Centrifugal FAD KW Specific Power 3 (kW/m /min)

3

Screw 650 5.8

112 m /min (3950 cfm) 549 4.9

Confederation of Indian Industry

521 4.65

Replacement of Inefficient Compressors

Compressor - Conveying Blended Cement Design Specifications
Capacity (FAD) = 34.32 m3/min
Pressure Motor = 5.5 kg/cm2 = 180 kW

Compressor Operated at Lower Pressure

Optimized by plant team @ 4.2 ksc (avg.)

5 year Old Compressor

Regular Maintenance Conducted Overhauling done
Confederation of Indian Industry

Replacement of Inefficient Compressors

Capacity Test Conducted
Actual volume (FAD) = 31.80 m3/min Volumetric Efficiency = 92% Operating Pressure Specific Power = 4.2 ksc = 5.471 kW per m3/min

Lower Operating Pressure Lower Specific Power

Confederation of Indian Industry

Replacement of Inefficient Compressors

Specific Power Norm
4.90 kW/m3/min for 7.0 ksc 3.185 kW/m3/min for 4.2 ksc

Energy Saving potential : 40% Replaced with New Reciprocating Compressor

Annual savings Investment Payback period = Rs. 10.59 Lakhs = Rs.10.00 Lakhs = 12 months

Confederation of Indian Industry

Segregate High-Pressure & Low-Pressure Compressed Air Users

Reciprocating Compressors
2700 m3/h x 5 nos.

Compressed Air Generation

7000 m3/h @ 7.4 ksc at generation Pressure at Receiver 6.0 ksc

Major users Interlacers & Instrumentation Requirement

4400 m3/h @ 4.5 ksc for interlacer 2600 m3/h @ 6.5 ksc for instrumentation
Confederation of Indian Industry

Segregate High-Pressure & Low-Pressure Compressed Air Users

At interlacers PRVs installed
After PRV pressure 2.2 ksc

Higher volume required at lower pressure Total volume at higher pressure Energy Inefficient Method - loss due to PRVs

Power Consumption Operating Pressure

Excellent Potential to Segregate Generation
Confederation of Indian Industry

Segregate High-Pressure & Low-Pressure Compressed Air Users

Dedicate 2 compressors for interlacer reqmt.
Operate at 4.5 ksc About 34% pressure reduction

Dedicate 1 compressor for instrumentation

Operate at the same existing pressure

Separate lines laid with PLC control system

Annual Savings Investment Payback period : Rs.31.86 lakhs : Rs.8.25 lakhs : 4 months

Confederation of Indian Industry

Centrifugal Compressor
Energy Efficient

Higher than Reciprocating and Screw

Behavior different from Reciprocating and Screw Ideal if user demand = Compressor Capacity

Efficient at 60-90% flow range

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Centrifugal Compressor Performance Curve

Natural Surge Point

Discharge Pressure

Surge Line

Natural Curve Rise to Surge

Throttled Surge Stall/ Choke

Volumetric Flow
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Capacity Selection
Capacity Sizing Very Crucial If Actual Capacity Required < Rated Capacity
Could end-up in Surge

Might lead to Blow-off

Alternatives
Impeller Reduction
Variable Speed Drive
Confederation of Indian Industry

Operating Pressure
Operating Pressure Process Related
If Actual Press. Reqd. < Operating pressure
Could Lead to Stall or Choke Compressor Delivers More Air Lead to Operation with Recirculation/ Venting

Alternatives
Impeller Reduction
Variable Speed Drive
Confederation of Indian Industry

Conversion of 2-stage Centrifugal Air Compressor to 3-stage

Earlier System
Battery of Compressors
Centrifugal Compressors - 700 HP x 3 nos. Reciprocating Compressors - 250 HP x 2 nos.

All Compressors in Operation

Centrifugal Compressor 2-stage
Confederation of Indian Industry

Conversion of 2-stage Centrifugal Air Compressor to 3-stage

Modified System
Converted All Centrifugal Compressors
2-stage to 3-stage Same Motor Retained

Only Air end changed

Air end comes along with Inter stage Cooler

Confederation of Indian Industry

Conversion of 2-stage Centrifugal Air Compressor to 3-stage

Benefits
8 % Savings Achieved Compressor Operation
(3 x 700 HP) - Centrifugal

Stopped Reciprocating Compressors

Annual Savings
Investment Simple Payback

: Rs. 80.00 Lakhs

: Rs.150.00 Lakhs : 23 months

Confederation of Indian Industry

Optimising compressed air system

Cooper-1 2050 cfm Cooper-2 2050 cfm IR-1 (C-25) 2391 cfm IR-2 (C-21) 2160 cfm IR-3 (C-15) 1520 cfm

ON

OFF

ON

OFF

ON

Typical operation
Cooper 1 IR-1 (C-25) IR-2 (C-15) or IR-3 (C-21)

To receiver

: 100% load : 100% load : Varying load

Majority of time IR-2 (C-15) in operation

Optimising compressed air system

Loading of compressors
Normal operation times (full load)

C-15/ C-21 on variable load

Off peak times C-15/ C-21 Unloads Other IR also unloads

Variable load of C-21

Loading Vent - 40% Potential to save - 10% Unloading - 40%

Part load

- 10%

Optimising compressed air system

Pressure in the common header
Normal times Off-peak times : 108-120 psi (Avg. 114 psi) : 118-132 psi (Avg. 125 psi)

Tremendous potential to save power Recommendation

Install new screw (oil free) compressor

1000 cfm capacity with VFD

Benefits
Reduction in system pressure (4%)

In all compressors
Unloading/ venting totally avoided Stable inlet pressure to intermediate controller

Optimising compressed air system

Annual savings Est. Investment

= S$ 61000 = s$ 120000

Simple payback

= 24 months

Compressed Air Pressure Real Time Data

82 80 78 76 74 72 70 68 66 64 62 60
11:05 12:15

PSIG

13:37 Time Confederation of Indian Industry

14:36

15:58

The problem with fluctuating Air Pressure

Higher Energy Consumption. Increased maintenance costs. Higher operating costs. Interruptions in production schedules.

Confederation of Indian Industry

Air In

Air Out

On Load

On Load

PSIG

Air In

Air Out

C/A Bypassed
Confederation of Indian Industry

Air In

Air Out

On Load

Unloaded

Air In

Air Out

Control System
Confederation of Indian Industry

Case Study: Automobile Industry

Before Control System : Energy Consumed = 11,760 kWh/day Main Header Pressure Variances = +/- 10 psig After Control System : Energy Consumed = 10,329 kWh/day Main Header Pressure Variances = +/- 1.0 psig

Energy Saving

= Rs. 29 lakhs

Total Project Cost

Simple Payback period

= Rs. 20 Lakhs
= 9 months.

Confederation of Indian Industry

Minimise Leakages

Common in all industries Tricky Quantification

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Quantification
Allow compressor to run normally Allow compressed air to flow in the system Close all the user points Measure the loading and unloading time

% of loading time is % of leakages

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Leakage Test
Close all the user points & Charge all the lines Note the Load time of compressor (T)

and
Unload time of compressor (t)

% air leakage (L) = [T/ (T + t)] x 100 Qty. of leakages = L x Compressor Capacity (Q)

Confederation of Indian Industry

Cost Of Leakage At 7kg/cm2

Power Orifice dia Air Leakage Annual Savings Wasted (mm) (cfm) @ Rs.3.50/kWh. (kW) 1.6 6.5 1.26 Rs.35,000 3.2 26.0 5.04 Rs.1,40,000 6.4 104.0 20.19 Rs.4,25,000
Confederation of Indian Industry

Replace Compressed Air with Blower Air for Agitation in ETP

ETP Agitation Very Important
Compressed air used in several industries Highly energy intensive 7 ksc pressure utilised for 8 depth tank Required pressure 0.5 ksc only Quantity consumed 120 cfm For Agitation - Quantity is Criteria, Not Pressure!!
Confederation of Indian Industry

Replace Compressed Air with Blower Air for Agitation in ETP

Specific Power Comparison
Compd. air : 15 kW per 100 cfm Blower air : 5 kW per 100 cfm ETP

Replaced with 7.5 kW blower

Capacity - 150 cfm Head - 0.5 ksc
Compressed Air Line

Annual Savings Investment Payback period

: Rs.3.36 lakhs : Rs.0.50 lakhs : 2 months

Confederation of Indian Industry

Use Transvector Nozzle In Air Hose

Sucks atmospheric air along with air jet
Reduces air consumption by 50%

Compressed air used for cleaning the burrs Provided transvector nozzles at the end users
Atmospheric Air

Annual Savings Investment Payback period

- Rs. 0.48 Lakhs - Rs.0.25 Lakhs - 6 months

Confederation of Indian Industry

Atmospheric Air

Compressed Air @ 7.0 KSC

Install Ball Valves At The User Point To Avoid Compressed Air Wastage
Background
Existing ball valve New ball valve to be provided

Compressed air header

Nozzle pipe Compressed air used for cleaning Every 2 mins. operator walks 10 to 15 feet to close valve

Action
Provide a ball valve at the end of the pipe Annual Savings - Rs. 3.60 lakhs
Confederation of Indian Industry

Compressed Air Dryers

Adsorption Type Refrigeration Type

Dessicant Heatless Type

Dessicant Heated Type

Dessicant Heat of Compression Type

Why Air Dryer? Water carryover damaging instruments Possible corrosion of receiver and air lines
Confederation of Indian Industry

Air Dryer - Dessicant Heatless Type

Dry air (to process) Purge air (12-15%) (to atmosphere) A in B Regeneration

100% saturated air (from compressor)

Confederation of Indian Industry

Air Dryer - Dessicant Heated Type

Dry air (to process)

Purge air (2%) (to atmosphere)

A
Purge

in Regeneration

Heater Blower 100% saturated air (from compressor)

Confederation of Indian Industry

Refrigeration Dryer
Dry air 15oC

Air, 100% saturated 7 kg/cm2, 28oC

17oC

2oC Drain Refrigeration Unit

Confederation of Indian Industry

Heat of Compression (HOC) Dryer

AC2
After-filter Dry Air (-40oC atmospheric dew point)

100%

Service

Saturated Air

Heating

AC1

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Heat Of Compression (HOC) Dryer

AC2
After-filter Dry air (-40oC atmospheric dew point)

100% Service

Saturated Air

Cooling

AC1

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Comparison of Air Dryers

Running Atmospheric Pressure Best Suitable Type of Dryer (cfm) Capital Cost Cost Dew Point oC Drop for Dessicant Heatless Dessicant Heated Dessicant HOC Refrigeration Dryer Low High High Medium High Very Low Medium Low -40 -40 -40 -20 Medium High High Low 150 100-750 >500 100

Confederation of Indian Industry

Replace Dessicant Heater Dryer With HOC Dryer

Plant had 5 Reciprocating Compressors
Used for Instrumentation

Drying by Dessicant Heater dryer

Dry air requirement - 50 m3/min

Heater capacity - 32 kW

Purge air loss

- 10% ~ 5m3/min
Confederation of Indian Industry

Replace Dessicant Heater Dryer With HOC Dryer

Benefits of Replacement
Heaters eliminated No purge air losses Required dew point achieved
Annual Savings Investment Payback period : Rs. 7.20 lakhs : Rs. 14.75 lakhs : 25 months

Confederation of Indian Industry

List Of Energy Saving Ideas In Compressed Air System

Select correct size air compressor Operate compressor at required pressure

Install VFD
Minimise system losses - Proper line sizing

Replace compressed air with blower air for agitation

Replace pneumatic tools with electric tools
Confederation of Indian Industry

List Of Energy Saving Ideas In Compressed Air System

Provide ball valves at the user point to avoid compressed air wastage Use transvector nozzles in air hoses Cool inlet air to the compressor Provide sensors to sense unloading and switch off Replace inefficient compressors Install high efficiency dryers
Confederation of Indian Industry

Thank you

Confederation of Indian Industry