Energy Efficiency MeasuresCOMPRESSED AIRMost manufacturing facilities use compressed air for at least some functions; for many plants, energy for compressed air systems is a substantial portion of the entire electric bill. Over 15% of total motor energy in the industrial sector goes to producing compressed air, yet compressed air systems are inherently inefficient, producing only one unit of useful work for every 5 units of energy input. Many compressor systems are poorly laid out and have leaking fixtures. Further, motor/compressor systems are frequently mismatched to loads.
If compressed air systems in use in the industrial sector were upgraded by taking advantage of all cost-effective efficiency measures, estimates are that 163 Trillion Btus of energy would saved at the source (power station), resulting in a dollar savings by industries of $777 million per year (at 5 cents per kWh). Suggestions for curbing energy waste in air compressor systems include the following:
This latter suggestion is very important. For a compressed air system in constant operation in a facility whose electric energy cost is 5 cents/kWh, a 1/16” diameter leak costs about $500 per year, a 1/8” diameter leak about $2,000 per year, and a 1/4” diameter leak about $8,000 per year. ResourcesThe Compressed Air Challenge is a voluntary collaboration of industrial users, manufacturers, distributors and their associations, consultants, state research and development agencies, energy efficiency organizations, and utilities whose aim is to improve the performance of compressed air systems. The Compressed Air Challenge offers training and a variety of resources, including excellent written material. For example, a copy of “Improving Compressed Air System Performance,” a sourcebook for industry that is a comprehensive outline of opportunities for energy savings with compressed air systems, may be downloaded for free as a PDF at www.compressedairchallenge.org/content/library/pdfs/compressed_air_sourcebook.pdf. A copy of Best Practices for Compressed Air Systems, a 300-page how-to-do-it document is available from the Compressed Air Challenge website for $95 plus shipping and handling; visit www.ucs.iastate.edu/mnet/compressedair/home.html. A detailed list of other helpful resources on compressed air may be found on the “Energy Solutions” web site of the Western Area Power Administration. Choose “Compressed Air” at www.energyexperts.org/energy_solutions. The U.S. Department of Energy’s Energy Efficiency and Renewable Energy Industrial Technologies Program works to improve the energy intensity of the U.S. industrial sector through research and development, validation, and dissemination of energy efficiency technologies and practices. You can access its extensive compressed air best management practices, case studies, tip sheets, technical tools, and other information at the link below. |
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