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To estimate electricity cost, convert motor horsepower to kilowatts and multiply by run time.
A more precise calculation would include input volts, amps, and power factor.
Convert horsepower to cubic feet per minute (CFM) to calculate running cost by air volume.
If the motor in the above example were increased to 92% efficiency, the annual electricity cost would be reduced to
$64,707.
Example Two:
Assume that you want to make a more precise calculation for a three-phase compressor. Example One does not include system losses
for belts, fans, pumps, and so on. Therefore, it is more accurate to measure input kW or input voltage and current. Using the same
scenario where the compressor runs 40% of the time (3,500 hrs/yr), the full-load amps, line-to-line voltage, and power factor are all
measured in this case. Electricity cost is $0.08/kWh. The monthly demand charge is $10/kWthe overall average cost of electricity with
demand charge is approximately $0.114/kWh.
Full-load amps = 280 amps
Line-to-line voltage = 460 volts
Power Factor (pf) = 0.82
First, find the kW usage for the three-phase motor:
kW = [volts x amps x pf x 1.732] / 1,000 = [460 x 280 x 0.82 x 1.732] / 1,000 = 183 kW
Annual Electricity Cost = kW x Hrs x Electricity Cost
Annual Electricity Cost = 183 kW x 3,500 hrs x $0.114/kWh
Annual Electricity Cost = $73,017
Note that in the second example, the electricity measurements are made in the circuit leading to the compressor motor, so that the full
power usage is measured. However, the motor efficiency is still a factor when one considers a possible motor change out, as noted in
Example One.
What does it cost per CFM (cubic foot per minute) of compressed air?
Example Three:
The following provides a ballpark estimate for a typical compressor running 6,000 hours annually, assuming a 90% efficient motor, 4
CFM is produced per 1 hp, and electricity cost is $0.08/kWh.
1 CFM = 0.25 hp = 0.25 hp/0.90 x 0.746 kW/hp = 0.207 kW
1 CFM = 0.207 kW (assuming a 90% efficient motor)
Annual Electricity Cost for 1 CFM = kW x Hrs x Electricity Cost
Annual Electricity Cost for 1 CFM = 0.207 kW x 6,000 hrs x $0.08/kWh
Annual Electricity Cost for 1 CFM = $99.50 or approximately $100/CFM
Reduce compressed air use in production wherever possible. Switch to motors, mechanical actuators, and other means to
accomplish the same function. Only use compressed air when it is absolutely necessary!
Reduce system losses. Leaks can represent 30% or more of air demand. Most leaks are at the point of use. Eliminate all timerwaste drains.
Lower system pressure where possible105 psi can cost 25% more than 95 psi in energy use. Do you really need that much
system pressure?
Use the appropriate unloading controls (modulating control) to reduce air usage and lower input energy where possible. In the
case where multiple units are involved, a modern electronic central air management system will keep all the units on at full load,
and only one unit at part load. The objective is to keep compressors off when they are not needed, thereby reducing energy
use.
The University of Minnesota offers other energy-saving tips, including recovering wasted heat for other processes, keeping inlet air
filters clean, and using cooler intake air.
References
"Compressed Air System Economics," Improving Compressed Air System Performance: A Sourcebook for Industry, U.S. Department of
Energy, Office of Industrial Technologies. Last accessed July 22, 2011.
"Air Compressor Energy-Saving Tips," University of Minnesota, Minnesota Technical Assistance Program. Last accessed July 22, 2011.
SCE&G Energy Insights has been prepared solely for the purpose of providing helpful information to users of this service. The information has been compiled
by Questline, a contractor to SCE&G; however, no representation is made by either Questline or SCE&G as to the completeness or accuracy of the
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