Air Compressors

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

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 %

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

Savings same as inter cooler - 7 % Higher than inter cooler Lesser than inter cooler
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

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?
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?
Optimal Utilisation of Compressors

Background 37 kW compressor in operation
At present loading - 30% Unloading - 70%
Power consumption
Unload - 9 kW Loading - 27 kW

Action
Install 15 kW package air compressor
Saves no-load power Use existing compressor as stand-by
Rs.
Rs.
Annual Savings Investment Payback period

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

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)


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
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
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

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

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


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
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

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

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
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

Centrifugal Compressor Performance Curve

Natural Surge Point
Discharge Pressure
Surge Line
Natural Curve Rise to Surge
Throttled Surge Stall/ Choke
Volumetric Flow
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
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
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

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

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
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

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%

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
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.
Air In
Air Out
On Load
On Load
PSIG
Air In
Air Out
C/A Bypassed
Air In
Air Out
On Load
Unloaded
Air In
Air Out
Control System
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.
Minimise Leakages
Common in all industries Tricky Quantification
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
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)
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
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!!
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
: Rs.3.36 lakhs : Rs.0.50 lakhs : 2 months
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
- Rs. 0.48 Lakhs - Rs.0.25 Lakhs - 6 months

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
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
Air Dryer - Dessicant Heatless Type

Dry air (to process) Purge air (12-15%) (to atmosphere) A in B Regeneration
100% saturated air (from compressor)

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)

Refrigeration Dryer
Dry air 15oC
Air, 100% saturated 7 kg/cm2, 28oC
17oC
2oC Drain Refrigeration Unit

Heat of Compression (HOC) Dryer

AC2
After-filter Dry Air (-40oC atmospheric dew point)
100%
Service
Saturated Air
Heating
AC1
Heat Of Compression (HOC) Dryer

AC2
After-filter Dry air (-40oC atmospheric dew point)
100% Service
Saturated Air
Cooling
AC1
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
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
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
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
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
Thank you

Air Compressors

Uploaded by

Copyright:

Available Formats

Air Compressors

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Air Compressors

Uploaded by

Copyright:

Available Formats

Energy Conservation

Air Compressors & Compressed Air System

Life Cycle Cost For A Compressor

Energy Cost 90%

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

> 12000 cfm

Disadvantage: Oil carry over

Single Acting, 2-Stage Reciprocating Compressor

Relief valve Trap (Drain)

Pressure switch Receiver

Inter-cooling reduces temperature & volume

Inter-cooler generally saves 7 %

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

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

After-cooler saves energy only when air dryers are installed

Methodology for Energy Audit

Is correct type of dryer used?

Confederation of Indian Industry

Methodology for Energy Audit

Are auto drain valves provided?

Confederation of Indian Industry

Optimal Utilisation of Compressors

Optimal Utilisation of Compressors

Annual Savings Investment Payback period

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

Optimal Utilisation of Compressors

Avg. loading : 17% (during normal running)

Optimal Utilisation of Compressors

capacity for normal operation

compressor to start automatically

Confederation of Indian Industry

Capacity Test (Pumping Method)

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

VR = Volume of air in receiver

Comparison of Specific Power Consumption

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

Screw 650 5.8

112 m /min (3950 cfm) 549 4.9

Replacement of Inefficient Compressors

Compressor Operated at Lower Pressure

5 year Old Compressor

Replacement of Inefficient Compressors

Lower Operating Pressure Lower Specific Power

Replacement of Inefficient Compressors

Energy Saving potential : 40% Replaced with New Reciprocating Compressor

Confederation of Indian Industry

Segregate High-Pressure & Low-Pressure Compressed Air Users

Compressed Air Generation

Major users Interlacers & Instrumentation Requirement

Segregate High-Pressure & Low-Pressure Compressed Air Users

Power Consumption Operating Pressure

Segregate High-Pressure & Low-Pressure Compressed Air Users

Dedicate 1 compressor for instrumentation

Separate lines laid with PLC control system

Confederation of Indian Industry

Higher than Reciprocating and Screw

Efficient at 60-90% flow range

Centrifugal Compressor Performance Curve

Natural Curve Rise to Surge

Throttled Surge Stall/ Choke