Do you want to reduce the cost of electricity associated with compressed air systems? More likely - you can. First, determine the annual compressed air electrical cost using the following formula:
Brake horsepower X 0.746 X years of operation hours X KWH [kWh] cost [divided by] motor efficiency
Note: 1 CFM [cubic feet per minute] @ 100 PSIG [table pressure per square inch] 8760 hours cost $110.00 per year electricity fee
Next... follow these top 7 compressed air energy saving tips:
1. Repair your air leak
If you do not take any other measures - please follow these tips: Find and fix compressed air leaks. Air leaks are a problem in the industry. "The biggest loose"!
The average plant loses 20% to 30% of its compressed air through multiple small air leaks. It is worthwhile to spend money on manpower and parts to find and fix these leaks. Note [1/4" holes will flow through 103 cfm @ 100 psig]
2. Switch to synthetic lubricants
If you are using a petroleum-based lubricant, switching to Compressor Synthetic Lubricants can save up to 8% of your energy. Longer equipment life, saving oil and processing costs.
3. Reduce plant operating pressure
If possible - reduce overall plant pressure. Less stress> Less CFM used > lower energy consumption.
Tip: Reduce the factory pressure by 2 pounds at a time, then test the run for at least 24 hours. If there is a problem with any equipment... then increase the pressure by 2 pounds until it runs smoothly again. Every 2 pounds of pressure reduced - you can save 1% on electricity costs to run an air compressor.
4. Check the differential pressure of the air compressor filter.
Start with the compressor cabinet filter and check the compressor inlet filter.
Note: Dirty inlet filters can cost between 1% and 3% additional electricity. why? Because the reduced air flow to the compressor inlet valve increases the compression ratio, resulting in more run time.
Next check the air/oil separator differential pressure at full load. The new separator results in a differential pressure drop of approximately 2-3 psig. When the pressure drops to 8-10 psig, the separator element needs to be replaced. Dirty separator components can cost you up to 5% extra power.
Next replace the control air filter element. This is usually a filter that looks, but still important, where the controller receives their air signal. The pressure drop here causes the controller to receive a lower pressure signal, thereby loading the compressor more and using more power.
5. Reduce compressor inlet temperature
By reducing the intake air temperature to 10°F below 70°F, you can save 2% of your electricity usage. On days of 30°F, your benefits increase by up to 8%. However, increasing the inlet temperature to 70°F above 10°F requires 2% for every 10°F increase and 10% for 120°F. [Import temperature has little effect on the lubrication screw compressor]
6. Check the differential pressure of the compressed air line filter.
The size compressed air filter is twice the compressor CFM flow rate [2x]. This will reduce your pressure drop by about 2-3 psig and save 1% in energy costs. The element will last twice [2x] and you will save on maintenance costs.
7. Understand the quality of compressed air your plant needs.
The more energy you can clean and dry compressed air.
Please contact your equipment manufacturer to determine the required air quality.
Orignal From: Top 7 compressed air energy saving tips
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