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Due to inefficiencies in
the production of power
(only 34% efficient) and
the subsequent use of
electricity to drive
compressors. Only 4%
of the initial energy is
converted to useable
energy in the
compressed air
Compressors
Rotary Screws
Reciprocating
Centrifugal
Choosing the Right Compressor
Compressor Type, Efficiencies and Sizes
Specific power
Part load
Type Range, cfm consumption,
efficiency
kW-100 cfm
2-25 24-26 Good
Lubricated piston 25-250 18-22 Good
250-2500 16-19 Excellent
2-25 24-26 Poor
Oil injected screw 25-250 18-22 Fair
250-2500 17-19 Fair
25-250 20-25 Good
Oil free screw
250-2500 16-20 Good
500-2500 18-22 Excellent*
Centrifugal
>2500 16-18 Excellent*
* Within turndown range
Choosing the Right Compressor
The type of compressor you choose will depend on your system pressure,
capacity, quality requirements and the shape of the demand pattern.
Systems with steady, high demands might opt for a series of centrifugal
machines.
Systems requiring extremely high quality air should opt for Oil-free designs
Reduce Leakage
•Compressed Air leaks can account for the majority of a sites usage
•Simple measures can increase pressure to the end user
How to Reduce your
Compressed Air Costs
Compressor
Water
separator Afterfilters
Dryer
Compressor Prefilter
Receiver
Particulates:
Class Maximum number of partic les per m
3 Particle size Concentration
Particle size
≤0.1um 0.1<d≤0.5um 0.5<d≤1.0um 1.0<d≤5.0um mm Mg/m
3
°C
0 As specified by the
equipment user or supplier
and more stringent than
1 <= -70 class 1<=0.01
2 <= -40 <=0.1
3 <= -20 <=1
4 <= +3 <=5
5 <= +7
6 <= +10
Choosing the Right Treatment
Different Dryers for Different System Dewpoints
+3 Refrigerant General 3%
purpose
§Refrigerant
–Low energy and capital cost
provide pressure dewpoints to
+3oC
§Desiccant dryers
–Essential for lower dewpoints,
expensive to operate. Look for
alternative regeneration methods
such as steam and external
blowers.
Choosing the Right Treatment
System Filtration
§Dust/water separators
–Mechanical cyclonic separators
§ Condensate is too
contaminated for direct
discharge to drain
Results of Previous Work
The Main Causes of Loss are:
§Inefficient Generation & Treatment
–Poor compressor control
–Poor efficiency
–Incorrect sizing
§Pressure drops in treatment and distribution systems
§Leaks
§Misuse of air - cooling, product ejection & ventilation
§Waste heat not recovered
Breakdown of Savings Identified During Carbon Trust Surveys in Northern Ireland
distribution improvements
1.5% treatment improvemenst
0.5%
new compressors
1.8%
etraps other
vsd 2.9% 1.5%
5.7%
Pressure reduction Leakage reduction
6.0% 32.4%
compressor control
7.0%
heat recovery
12.6%
compressor efficiency
misuse reductions improvemnts
13.7% 14.4%