Compressed Air

Approximately 70 percent of all manufacturers have a compressed air system. These systems power a variety of equipment, including machine tools, material handling and separation equipment, and spray painting equipment. Energy audits conducted by the U. S. Department of Energy (DOE) suggest that over 50 percent of compressed air systems at small to medium sized industrial facilities have energy efficiency opportunities with low implementation costs.

Compressed air is one of the most expensive uses of energy in a manufacturing plant. About eight horsepower of electricity is used to generate one horsepower of compressed air. Calculating the cost of compressed air can help you justify system improvements that increase energy efficiency.

The links below will help you calculate the cost of compressed air use, understand your compressed air system and identify easy to implement energy efficiency strategies for compressed air systems.

Air Compressor Energy-Saving Tips Approximately 70 percent of all manufacturers have a compressed air system. This fact sheet about air compressors will help you calculate their operating cost, understand your system and identify easy to implement energy efficiency strategies.

AirMaster+ Software This compressed air system assessment and analysis software package helps maximize the efficiency and performance of compressed air systems through improved operations and maintenance practices. Find under “Tool Box.”

Assessing Compressed Air Needs Carefully assessing your company’s compressed air needs will ensure that the system is configured correctly. Compressed air needs include air quality, quantity and level of pressure necessary for the end uses in your plant.

Compressed Air System Audits Comprehensive compressed air system audits are performed by several different types of firms and receiving one can help your company improve efficiency and productivity. An audit should contain an assessment of both air supply and usage and the interaction between the supply and demand.

Compressed Air System Controls Compressed air system controls are one of the most important determinants of overall system energy efficiency.

Compressed Air System Economics Compressed air system costs can really add up, but improving the performance of the system can save your company a significant amount of money.

Compressed Air System Leaks Leaks can be a major cause of wasted energy in a compressed air system. Proactive leak detection and repair can be accomplished by implementing a leak protection program.

Energy in the Air Over the life of an air compressor, energy costs will be five to 10 times the compressor's purchase cost. Use the tips in this article to ensure that your air compressors are running as efficiently as possible.

Heat Recovery with Compressed Air Systems As a way to save energy, heat from the electrical energy used by compressed air systems can be recovered for various uses throughout the shop like industrial process heating.

Inappropriate Uses of Compressed Air Compressed air can be the most expensive form of energy in a plant and it is important to consider more cost-effective, alternative forms of power before using it.

Kaeser Compressors—Achieve Significant Savings through Improved Energy Management Overall operating power costs are impacted significantly by the air compressor package. To help minimize energy wasted at the air compressor site use energy efficient components, state-of-the-art control systems, and look for equipment that maintains low pressure drop over its entire service life.

Listening for Leaks MnTAP staff can help you find compressed air and steam trap leaks using an ultrasonic leak detector.

Maintenance of CA Systems for Peak Performance Periodic maintenance can help your compressed air system operate at peak efficiency and minimize unscheduled downtime.

Packaged Compressor Efficiency Ratings The Compressed Air and Gas Institute (CAGI) has developed performance testing standards to help with the daunting task of evaluating and comparing air compressor capacities and efficiencies.

Pressure Drop and Controlling System Pressure Minimizing pressure drop is helpful to avoid excessive energy consumption and requires a systems approach in design and maintenance of the system. Controlling system pressure is another opportunity to achieve significant savings.

Proven Opportunities at the Component Level Analysis of the individual components of compressed air systems can help enhance the efficiency of your overall system.

Top Compressed Air Energy Saving Options Compressed air assessments at metal casters, pulp and paper mill, and mines reveal that facilities have common opportunities for energy efficiency improvements: storage, sequencing and removing inappropriate uses.

U.S. Department of Energy's (DOE) Office of Industrial Technologies (OIT) BestPractices DOE OIT BestPractices works with industry to identify plant-wide opportunities for energy savings and process efficiency through implementing new technologies and systems improvements. BestPractices provides an assortment of tools and resources to help industrial end users achieve efficiency improvements and related cost savings.

Industrial Case Studies
Compressed Air Project Improves Efficiency and Production at Harland Publishing Facility The John H. Harland Corporation reconfigured a new type of printing machine that uses less compressed air and requires a lower pressure to operate effectively. The project allowed Harland to avoid spending more than $500,000 for additional compressors that would have led to over $200,000 per year in energy and maintenance costs. The project’s implementation improved the performance of the new printing machines, which has led to better product quality and reduced production cycle time.

Compressed Air System Upgrade Results in Substantial Energy Savings BWX Technologies completed a retrofit project on the compressed air system. The replacement of antiquated compressors and dryers, along with the implementation of a more sophisticated control strategy, significantly improved the efficiency of the compressed air system and led to important savings in energy and maintenance costs and reduced the need for wastewater treatment. Annual energy savings totaled $264,000, or 4.2 million kWh, with a payback of less than 2 years.

Using Compressed Air Evaluate your compressed air use. K-Bar uses compressed air to blow powder paint off its racking. A MnTAP site visit helped World Aerospace Corporation determine that closed loop cooling was not economically feasible for the size of its compressor.

Water Heater Company Saves $160,000 Annually with Compressed Air System Improvements The American Water Heater Company (AWHC) improved its compressed air system that serves its manufacturing plant. This enabled the system to support the plant’s production processes more effectively, significantly improving product quality and allowing for greater production. Annual energy savings totaled $160,000 with a payback of 17 months.

Resource Organizations
Compressed Air Challenge This voluntary collaboration of manufacturers, distributors and others develops and provides resources to industry on the opportunities to increase net profits through compressed air system optimization. Its Web site has technical information, case studies, reports and resources, and training announcements.