Lowering Your Compressed Air Energy Costs TreyDonzeMikeHotzAirTechnologies降低压缩空气能源费用LoweringCompressedAirEnergy课件Why Care About Compressed Air? Compressed air is expensiveCompressed air is essential to plant productivityCompressed air systems can be effectively managed to improve plant operationCompressed air systems usually have significant opportunities for efficiency improvement降低压缩空气能源费用LoweringCompressedAirEnergy课件Compressed Air Use in Selected Manufacturing IndustriesCompressed Air Energy Use as a Percentage of Total Electricity UseChemicalsPetroleumMetalsFoodPaper降低压缩空气能源费用LoweringCompressedAirEnergy课件Life Cycle Cost of an air compressorlEnergycostcanaccountforupto90%overatenyearworkinglifelWithin12months,thecapitalcostisusuallyexceededbytherunningcostslFirstcostrepresentsthelowestofthethreecostslEnergyconsumptionbyfaristhemostsignificantfactorinoperatingcostofanaircompressorInvestmentInstallationMaintenanceEnergy consumption降低压缩空气能源费用LoweringCompressedAirEnergy课件lTomakeanaccuratedeterminationofenergysavingssolutions,itisimportanttomeasureyoursystemflow,pressureandkWaswellasevaluateanyplansforfutureexpansionlThisisaccomplishedbyaflowandkWsurveyBenchmark Your Systems Efficiency降低压缩空气能源费用LoweringCompressedAirEnergy课件MeasureyourcompressedairrequirementsFlowPressureDewpointkWandkWhBenchmarkyourcurrentsystemsefficiencykWh/MCFReceiveadetailedreportoutliningimprovementsBenchmark Your Systems Efficiency降低压缩空气能源费用LoweringCompressedAirEnergy课件KW Meters降低压缩空气能源费用LoweringCompressedAirEnergy课件降低压缩空气能源费用LoweringCompressedAirEnergy课件lTypical24hrs/dayoperationwithlownightshiftandhighdayshiftconsumption.Steadyweekendconsumption(leakages).l(64%ofinstallations).time降低压缩空气能源费用LoweringCompressedAirEnergy课件降低压缩空气能源费用LoweringCompressedAirEnergy课件lFivedays/weekoperation,erraticdemandfluctuationsl(28%ofinstallations).time降低压缩空气能源费用LoweringCompressedAirEnergy课件Energy Reduction OpportunitiesUseEfficientCompressorControlsReduceCompressedAirUsageLowerCompressorDischargePressureEfficientlySequenceAirCompressorsOperateandMaintainCompressedAirEquipmentatPeakEfficiency降低压缩空气能源费用LoweringCompressedAirEnergy课件% Capacity% Power Input降低压缩空气能源费用LoweringCompressedAirEnergy课件75 HP Lubricated screw compressor w/ Modulation Control -vs.- 60 HP VSDAverage electrical cost = $0.06 / KWHRA) 1st shift250 CFM2200 HRS/YRB) 2nd shift175 CFM2200 HRS/YRC) 3rd shift100 CFM2200 HRS/YR75 HP unit 125 PSIG60HP VSD 125 PSIG82.5 Bhp full load power66 Bhp full load power320 CFM 290 CFM91.5% Motor eff.94% Use Efficient Compressor Controls降低压缩空气能源费用LoweringCompressedAirEnergy课件降低压缩空气能源费用LoweringCompressedAirEnergy课件Use Efficient Compressor Controls75 Hp modulating60 Hp VSD250 CFM:250/320=78%(93%Bhp)250/290=86%(86%InputkW)175 CFM:175/320=55%(86.5%Bhp)175/290=60%(61%InputkW)100 CFM:100/320=31%(79%Bhp)100/290=34%(38%InputkW)降低压缩空气能源费用LoweringCompressedAirEnergy课件Use Efficient Compressor Controls75 HP lubricated screw with modulation controlA) First shift 250 CFM:82.5 Bhp X (.93 factor) X .746kW X $.06 X 2200Hrs = $8,738.915 Mtr. eff. Hp kWhB) Second shift175 CFM: 82.5 Bhp X (.865 factor) X .746kW X $.06 X 2200Hrs = $8,127.915 Mtr. eff. Hp kWhC) Third shift 100 CFM:82.5 Bhp X (.79 factor) X .746kW X $.06 X 2200Hrs = $7,422.915 Mtr. eff. Hp kWh Total = $24,287降低压缩空气能源费用LoweringCompressedAirEnergy课件Use Efficient Compressor Controls60 Hp Variable Speed compressorA) First shift250 CFM: 66 Bhp x .746 kW x (.86 factor) x $.06 x 2200Hrs = $5,946.94 ME. HpkWhB) Second shift 175 CFM: 66 Bhp x .746 kW x (.61 factor) x $.06 x 2200Hrs = $4,217.94 ME HpkWhC) Third shift100 CFM:66 Bhp x .746 kW x (.38 factor) x $.06 x 2200Hrs = $2,627.94 ME Hp kWhTotal = $12,790降低压缩空气能源费用LoweringCompressedAirEnergy课件Total Power Savings:$24,287 - $12,790 = $11,497 per year60 HP VSD costs $25,000 for a 2.17 year payback!Use Efficient Compressor Controls降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageEliminateinappropriateairusersUsebrushes,blowers,orvacuumsystemsinsteadofcompressedairtocleanpartsorremovedebris;Useblowers,electricactuators,orhydraulicsinsteadofcompressedairblaststomoveparts;Usehighefficiencynozzlesinsteadofopenorifices降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageEliminateinappropriateairusersUsefanstocoolelectricalcabinetsinsteadofcompressedairvortextubesApplyavacuumsysteminsteadofusingcompressedairventurimethodsUseblowersinsteadofcompressedairtoprovidecooling,aspirating,blowguns,airlances,agitating,mixing,ortoinflatepackaging降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageMinimizeunregulatedairusersInstall regulatorsReducedpressurelowersairconsumptionUnregulatedusersuse47% morecompressedairat110vs.70PSIGLessequipmentwearandtear降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageShutoffairtoequipmentthatisshutdownorabandonedInstallautomaticsolenoidvalvesValveoffidledsectionsoftheplant降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageFixLeaksLeakscanaccountfor10-50%ofthetotalcompressedairusage!1/8inchdia.hole=25SCFM=$3,0001/4inchdia.hole=100SCFM=$12,0003/8inchdia.hole=230SCFM=$26,000*Based on 8,760 operating hrs/yr $0.07 per kWh energy cost降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageMinimizeLeaksMeasureleakloadtoquantifytheopportunityFindtheleakswithanultrasonicleakdetectorTagtheleaksFixtheleaksRe-measuretheleakloadtoquantifythesavingsDevelopandon-goingleakreductionprogram降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageReduce plant system air pressureUnregulatedairusersandairleaksuse28%morecompressedairat120vs.90PSIG降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageReducesystemairpressureEvaluatethepressurerequirementsofallcompressedairusersPutthesmallhighpressureuseronitsowncompressorInstallgoodcompressorsequencingcontrolsLowerthesystemairpressure降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce System Air PressureMeasuresystem/componentpressuredropsMinimizedistributionandcomponentpressuredropsLoopairheaderUpgrade,repairoreliminatehighdeltaPcomponentsUpsizepiping/hosesAddresslargeintermittentair“gulpers”thatdrawthesystemdownwithstorageandmeteringvalvesDecentralizecompressors降低压缩空气能源费用LoweringCompressedAirEnergy课件ReceiverSizing Useful Free Air Stored = V x P 14.7 V = storage volume (Ft3) P = pressure differential (Pressure Drop in Tank)Example:Pneumaticconveyorrequires200cfmof40psigairfor2minutesevery10minutes.200X2=400CFrequiredusefulfreeairtobestored P= 100-40=60400=VX60/14.7V=400X14.7/60=98CF=735gallons400CF/8minutes=50CFMtorefillSystemsees50CFMinsteadof200CFM!降低压缩空气能源费用LoweringCompressedAirEnergy课件Lower System Pressure to Lower Air Consumption70 psig 700 CFM air usage85 psig 825 CFM air usage95 psig 950 CFM air usage降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageReducesystemairpressureUseintermediatecontrollerswithstoragetoregulatesystemairpressureEffectivewhenpartoftheplantoperatesatalowerpressureLowersairconsumptionDoes not lower compressor pressure降低压缩空气能源费用LoweringCompressedAirEnergy课件Reduce Compressed Air UsageReducesystemairpressureUseeffectivecompressorsequencing,storage,andcompressorcontrolsto“regulate”systempressureLowers air consumption and compressor pressureMost energy efficient降低压缩空气能源费用LoweringCompressedAirEnergy课件Sequence Air Compressors降低压缩空气能源费用LoweringCompressedAirEnergy课件Typical System Without a SequencerCascading SystemsC1C2C3C4unloadloadlIndividualsettingslLargepressurebandlMultipleunitsatpartloadlVeryinefficient100 PSIG110105115110120115125 PSIG125100降低压缩空气能源费用LoweringCompressedAirEnergy课件Sequencers Significantly Improve Efficiency to Minimize Energy CostsCanregulatesystempressurewithin3-5psiLowersystempressuresignificantlyreducesairdemand(leaksandunregulateddemand)Operatestheminimum#ofcompressorstomeetthedemandOnlyonecompressortrimsatalltimesAutomaticscheduledsystempressurechangesand/orstart/stopofsystemMostefficientcompressorsequenceorderdeterminedfromflowdataCanautomaticallyselectoptimumsequence降低压缩空气能源费用LoweringCompressedAirEnergy课件System Pressure remains consistent as flow rate varies降低压缩空气能源费用LoweringCompressedAirEnergy课件Power consumption increases 1% for every 2 psi increase in compressor pressure RULE OF THUMB降低压缩空气能源费用LoweringCompressedAirEnergy课件EXAMPLE-4-100HpCompressorsRequired:1700SCFMat100PsigPressureSwitchSettingsBetween95to125PsigPressureBandof30 Psig400Hpx.745kW/Hpx8800/yearx.06kWh=$167,387.00.94(motorEfficiency)ReducePressureBandby25 Psigtosave12%=$20,086.00 Sequencerspay for themselves in energy savings by reducing pressure band differentials and lowering air usage降低压缩空气能源费用LoweringCompressedAirEnergy课件Flow changes but kW does not change proportionally降低压缩空气能源费用LoweringCompressedAirEnergy课件Poor efficiency of a cascaded system due to multiple units at part load降低压缩空气能源费用LoweringCompressedAirEnergy课件Sequencers Can Significantly Improve Efficiency to Minimize Energy CostsTotal system energy savings of 20-50% are expected降低压缩空气能源费用LoweringCompressedAirEnergy课件kW/100 CF stays consistent even under varying loads.32 kW/100CF versus .85 kW/100CF (63% Savings!)降低压缩空气能源费用LoweringCompressedAirEnergy课件SwitchtoLILOSequencingwitha5minuteunloadedtime降低压缩空气能源费用LoweringCompressedAirEnergy课件Sequencing Significantly Improves Efficiency to Minimize Energy CostsBasis3shiftoperation,$.06/kWhr,20PSIpressurebandreduction降低压缩空气能源费用LoweringCompressedAirEnergy课件SystemflowandpressureareloggedautomaticallyDeterminethemostefficientcompressorsequenceUsefulforpeakloadsheddingMeasureleaksSpotsystem/productionproblemsMeasureequipment/processairconsumptionAdvanced sequencers provide system flow and pressure data to manage your 4th Utility降低压缩空气能源费用LoweringCompressedAirEnergy课件 ManagAIR by Air Technologies System Report for Ferro 9/7/01 1:59:05 PMAlarm: No Faults DetectedCurrent System Readings- Pressure=108 Flowrate=1347 Sequence=2,1,3Previous 8hrs Data: Hour1 Hour2 Hour3 Hour4 Hour5 Hour6 Hour7 Hour8 Min Pressure 104 104 104 104 104 104 104 104Avg Pressure 108 108 109 109 109 109 109 109Max Pressure 114 114 114 114 114 114 114 114Min FlowRate 1274 1274 1311 1322 1324 1349 1311 1305Avg FlowRate 1448 1468 1648 1647 1739 1870 1644 1718Max FlowRate 2274 2298 2504 2485 2545 2629 2409 2432Min DewPoint -44 -43 -43 -43 -40 -36 -32 -21Avg DewPoint -41 -41 -36 -40 -37 -33 -25 -15Max DewPoint -39 -39 -11 -37 -35 -30 -19 -10Compressor Data #1 ZT25 #2 ZT25 #3 ZT25 NONE NONE NONE NONE Delivery Air Press 110 113 107 DP Air Filter -.01 -.1 .01 Intercooler Pressure -9 30 1 Oil Injection Press 28 28 0 Delivery Air Temp 93 93 86 Oil Injection Temp 122 124 90 LP Outlet Temp 351 352 95 HP Outlet Temp 363 372 91 HP Inlet Temp 99 104 91 Cooling Medium Inlet Temp 91 91 86 MD Regen Air Out Temp 129 162 84 MD Wet Air In Temp 97 99 81 LP Element Temp Rise 260 261 9 HP Element Temp Rise 264 268 0 Cooling Water Temp Rise Oil Cooler Approach Temp 31 33 4 Aftercooler Approach Temp 2 2 0 Intercooler Approach Temp 8 13 5 MD Regen Temperature Drop 234 210 7 MD Inlet Temperature Diff 4 6 -5 Loaded Hours 7358 7579 8773 Running Hours 11048 11616 12606 Compressor Status UNLOADED LOADED STOPPED Motor Starts 1717 1042 1060 Link Type MKIII MKIII MKIII Isolated/Integrated CENTRAL CENTRAL CENTRAL Full Feature Dew Point Oil Filter Remaining Lifetime 2423 1413 952 Oil Filter Total Lifetime 4000 4000 4000 Oil Remaining Lifetime 4952 4383 3475 Oil Total Lifetime 16000 16000 16000 Hours Until Regrease Bearings 848 286 3471 Hours Between Bearing Regreasing 4000 4000 4000 DailySystemReportandgraphfaxedore-mailedtoyouautomatically降低压缩空气能源费用LoweringCompressedAirEnergy课件InletFilters Every 4 inches (water) pressure drop reduces the compressor capacity 1%A dirty inlet filter can rob you of 5% or more!Good Maintenance Saves Energy降低压缩空气能源费用LoweringCompressedAirEnergy课件DirtyCoolers For every 11oF deterioration in the intercooler approach or increase in water temperature, the power consumption will increase by 1%.Good Maintenance Saves Energy降低压缩空气能源费用LoweringCompressedAirEnergy课件For every 10oF deterioration of the after cooler approach temperature, the dryer load is increased by as much as 46%.DirtyCoolersGood Maintenance Saves Energy降低压缩空气能源费用LoweringCompressedAirEnergy课件A dirty oil separator can increase your HP 5%DirtyOilSeparatorGood Maintenance Saves Energy降低压缩空气能源费用LoweringCompressedAirEnergy课件Energy Reduction OpportunitiesUseEfficientCompressorControlsReduceCompressedAirUsageLowerCompressorDischargePressureEfficientlySequenceAirCompressorsOperateandMaintainCompressedAirEquipmentatPeakEfficiency降低压缩空气能源费用LoweringCompressedAirEnergy课件Lowering Your Compressed Air Energy Costs TreyDonzeMikeHotzAirTechnologies513-539-6747降低压缩空气能源费用LoweringCompressedAirEnergy课件