Beatrice Lang
Compressors are essential to countless industrial processes, but they also consume a lot of energy—over 10% of the world's electricity. With energy prices on the rise, this can be costly for businesses. Fortunately, there are ways to reduce energy consumption and costs. This includes using smart air compressors, ensuring the right-sized compressor for your needs, and using Variable Frequency Drives (VFDs) or Variable Speed Drives (VSDs) to match the compressor's motor speed with the actual air demand. Other ways to improve efficiency include using cool, clean, dry intake air, regular maintenance, and minimizing artificial demand. These steps not only save money but also help fight climate change and protect the environment.
| Characteristics | Values |
|---|---|
| Temperature | Cool air requires less energy to compress. |
| Composition | Clean intake air ensures smoother movement of compressed air through the system. |
| Humidity | Dry environments are optimal for compressed air systems. |
| Belt tension | A belt that is too tight or too loose can cause inefficiency. |
| Lubrication | Keep all moving parts lubricated to avoid friction and prevent energy loss. |
| Artificial demand | Ensure applications only get the air volume and pressure they require to reduce waste. |
| Storage | Storage can control demand events during peaks by reducing the rate of decay and the amount of pressure drop. |
| Size | A compressor that is too big will be inefficient. |
| VFDs | Variable frequency drives reduce the compressor motor’s speed to match the actual air demand, reducing energy consumption. |
| VSDs | Variable speed drive air compressors produce maximum airflow with minimal electricity usage. |
| Setup | Ensure your setup is optimal for your needs. |
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What You'll Learn
Ensure the compressor is the right size for your needs
When it comes to air compressors, bigger is not better. A compressor that is too large for your needs will use more energy and consumables than a right-sized compressor. For example, if a compressor produces 500 cubic feet per minute (CFM) but the air requirement is only 300 CFM, then the compressor will be in an unload condition for a significant portion of the time. Screw compressors are inefficient in the unload condition and, thus, a larger compressor will be wasteful.
To ensure your compressor is the right size, you can conduct an energy audit to accurately measure the base and trim load demand. The base load is the minimum demand over a period of time, while the trim load refers to spikes in demand during a cycle. If the unload hours are 15-20% of total run hours, there is potential to save energy through a Variable Frequency Drive (VFD) compressor.
VFD compressors are highly effective ways to save energy during a compressor application. They work by reducing the compressor motor’s speed to lower flow to match the actual air demand. By reducing the motor’s speed, the compressor consumes less energy than a fixed-speed compressor.
Another way to ensure your compressor setup is optimal for your needs is to use compressed air storage. Storage can control demand events during peak demand by reducing the rate of decay and the amount of pressure drop. It can also protect critical operations from other events in the system by turning off a compressor if necessary.
Finally, it is important to minimize artificial demand. This means ensuring that applications only get the air volume and pressure they require, reducing waste. Regulating pressure at the end-use can minimize artificial demand, preventing overuse of the system.
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Cool the intake air
The temperature of the air that a compressor takes in has a significant impact on its efficiency. Cooler air is denser and already more compressed than warm air, and therefore requires less energy to compress further. Conversely, using hot air with lower density can significantly reduce productivity.
To lower electricity demand, it is therefore important to cool the intake air. One way to do this is to move the compressor intake into a shaded area outside, where the air is cooler. A reduction in temperature of 20 degrees Fahrenheit can lower operating costs by almost 3.8%. For every 6-degree Fahrenheit drop in intake air temperature, there is approximately a 1% increase in compressor efficiency.
Another method is to use an inlet air cooling system, such as an optimized M-cycle or a dew point indirect evaporative cooler. This can increase net power and exergy efficiency by 30.1% and reduce the Levelized Cost of Electricity (LCOE) by 22.5%.
It is also important to ensure that the air intake is not located close to high-humidity areas, as this can reduce outlet pressure.
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Use multiple small compressors with sequencing controls
Oversized air compressors can be inefficient because they use more energy per unit while operating with a partial load. Using multiple small compressors with sequencing controls can be an effective solution. This setup allows for greater flexibility, as portions of the system can be shut down by simply turning off some of the compressors.
When using multiple small compressors, it is important to ensure that they are properly controlled and maintained. This includes regular inspections and adjustments to maintain optimal operational conditions. For example, belt tension should be monitored and adjusted as needed to prevent excessive wear or slippage, which can lead to reduced efficiency.
Additionally, the quality of intake air plays a crucial role in the performance and efficiency of the compressors. Cool air requires less energy to compress, so it is recommended to locate the compressor intake in a shaded area or use cooling methods to reduce the temperature of the incoming air. Clean intake air is also important, as dirt, dust, or other impurities can accumulate and cause wear and reduced storage capacity. Regular maintenance and cleaning can help improve air composition and enhance efficiency.
Another factor to consider is the use of Variable Frequency Drives (VFDs) or Variable Speed Drives (VSDs) in the small compressors. VFDs and VSDs alter the compressor motor's speed to match the actual air demand, reducing energy consumption compared to fixed-speed compressors. They eliminate the unload cycle, reduce operating pressure, and minimize losses due to leakage and pressure drops, resulting in significant energy savings.
By combining multiple small compressors with sequencing controls, proper maintenance, and the use of VFDs or VSDs, businesses can effectively lower their electricity demand and improve the efficiency of their compressed air systems.
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Regularly maintain and clean the compressor
Regular maintenance and cleaning of your compressor can significantly enhance its efficiency and reduce electricity demand. Here are some essential tips to achieve this:
Firstly, ensure cold, clean, and dry air at the inlet of the compressor. Locate the air inlet away from dirt, dust, contaminants, and cooling towers. Keep the inlet air filter clean and replace it at least twice a year, or more frequently if your environment demands it. Monitoring the inlet air pressure differential gauge is also crucial; if it reads above 2-3 PSIG, change the filter immediately.
Secondly, maintain the cleanliness of the aftercooler and oil cooler. As temperatures rise, the aftercooler may accumulate dirt, leading to increased power consumption. A clean aftercooler helps to cool the recently compressed air, reducing moisture load on the dryer. Similarly, keeping the oil cooler clean is essential to prevent compressor oil from exceeding the ideal temperature range of 180-195°F. Above this range, the oil life shortens, and the oil's performance deteriorates.
Additionally, perform regular inspections of critical components, including safety valves, hoses, and electrical connections. Keep all moving parts lubricated with manufacturer-recommended lubricants to prevent friction and ensure smooth, efficient operation. Regularly check lubricant levels and be vigilant for any signs of contamination.
Finally, be proactive in detecting and addressing leaks. Leaks are a significant source of energy wastage, increasing costs and reducing the compressor's lifespan. Regularly inspect fittings, valves, pipes, and joints for any signs of leakage and repair them promptly.
By diligently following these maintenance and cleaning practices, you can optimize the efficiency of your compressor and substantially lower its electricity demand.
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Use a variable speed drive (VSD) air compressor
Compressing air consumes a lot of energy—over 10% of the world's electricity, in fact. This makes compressed air a major utility expense. Power consumption accounts for nearly 88% of a compressor's 10-year lifespan cost, and up to 50% of air is wasted, resulting in thousands of dollars lost in energy.
Variable Speed Drive (VSD) air compressors can help to reduce this waste and lower electricity demand. Unlike traditional fixed-speed compressors, which operate at a constant and consistent speed, VSD compressors adjust the amount of power used in response to CFM demand in real-time. This means that VSD compressors only run when needed, reducing energy costs.
VSD compressors use an intelligent drive system to continuously alter the motor speed to match the air demand. The drive controls the speed (RPM) of the unit, fluctuating the amount of power used to perfectly match the output required. This is achieved through an inverter, which provides the VSD compressor with the specific voltage required.
VSD compressors offer several benefits over fixed-speed compressors. They can start and stop under full system pressure, with no need to unload, saving time and energy. They also reduce power surges and avoid peak currents from starting the air compressor motor. VSD compressors are also more precise, with motor speeds that can be slowed down, brought to a halt, or revved up.
VSD compressors are ideal for facilities with fluctuating demand for compressed air, such as those with different processes or multiple shifts. They are not designed to operate continuously at full speed, and when they do, they are less efficient than fixed-speed compressors. However, for companies with varying compressed air needs, VSD compressors can provide significant energy savings.
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Frequently asked questions
Ensure your compressor setup is optimal for your needs. Use the latest data-driven tools to determine the right type of air compressor for your requirements.
A Variable Frequency Drive (VFD) reduces the compressor motor's speed to lower flow and match the actual air demand of the customer. This reduces the motor's power consumption.
Cool air requires less energy to compress, making it more efficient. A reduction in temperature of 20 degrees Fahrenheit can lower operating costs by almost 3.8%.
