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Energy Savings in Compressed Air Systems
“Energy Savings in Compressed Air Systems” was published in 2005 to cover the demand side of a compressed air system. The material is based on the findings of more than 1,200 air audits conducted throughout the world. This book helps you find and understand the demand side opportunities to lower the expenses associated with producing compressed air. Projects often have pay back periods of less than six months, and can improve the productivity of the manufacturing process. The details and case studies can be used for training or as a guide for solving problems – and making improvements in your facility. It is recommended reading for everyone involved with a compressed air system.
You should get a copy if you work with compressors or a compressed air system. The ideas will help you pinpoint and quantify the energy saving opportunities in your facility. The following is an example of the useful information you will find in this book.
Open Blowing Regardless of application, there are several guidelines that should always be applied to compressed air being used for open blow off:
At 60 psig, a blow gun on a 1/8 inch line will use approximately 10 cfm. A blow gun on a 1/4 inch line will use approximately 25 cfm. One savings approach is to use an air amplifier, which requires less compressed air. Air amplifiers use “venturi” action to pull in significant amounts of ambient air and mixing it directly into the air stream, which amplifies the amount of air available at the point of use. Air amplifiers have amplification ratios up to 25 to 1. Using 10 cfm of compressed air can supply 250 cfm of blow off air to the process, and generate a savings of 15 cfm compressed air per 1/4 inch blow off. Savings may be available using 1/8 inch lines, but the cost effectiveness will not be as great. The impact can be seen in the comparison below which uses standard OHSA blow guns regulated to 30 psig with a utilization rate of 20% and a power rate of $0.05 per KW. A standard blow gun, without a venturi nozzle, will use 14 cfm and will deliver 14 to the process. The annual energy cost is $262 (3KW x .05 x 8760 x .20). Adding a venturi nozzle to the same standard blow gun will reduce energy cost by more than 40% while supplying more air. The blow gun with a venturi nozzle will use 7 cfm and will deliver 175 cfm to the process. The annual energy cost is $153 (1.75KW x .05 x 8760 x .20).
Application and Installation
Guidelines Air supplies often have condensed water vapor in the air lines. This condensation leads to rust and dirt in the air lines. Also, some compressors will allow oil or oil vapor to enter the lines. Small orifices in the air saver products may become clogged with these contaminants. A 5 micron filter will separate 99% of the foreign material from the air supply allowing virtually maintenance free operation. The use of an oil filter will remove the oil droplets with an effective filtration of 0.01 ppm for an even cleaner air supply. Size these filters for flows greater than the amplifier requires. Keep in mind that the current line of air might contain dirt or oil, and it should be blown out before installation. Also, pipe thread sealant or tape must be carefully applied to avoid clogging orifices in air saver products. To obtain maximum performance from the air saver products, accurate measurements of air pressure (psi) and air volume (cfm) must be obtained. Line pressure of 70 to 90 psi can be present without sufficient volume (cfm) of air. To ensure that both pressure and volume are present to efficiently operate the air saver products, a line size of 1/4 inch pipe or 1/2 inch hose should be used for applications up to 10 feet from the main header. Use 3/8 inch pipe or 3/4 inch hose up to 20 feet, and 3/4 inch pipe and 1/4 inch hose up to 50 feet. Do not use coiled hose as the very small inside diameter of the hose limits air flow. Avoid 90 degree bends in the air hose or pipe for exit air to maintain flow.
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Table of ContentsThere are many subjects covered in this book. They have been organized into sections to make it enjoyable to read and easy to use for future reference. The section numbers are highlighted so you can click on them to see the topics covered in each section. Section 1: Compressed Air Your Most Expensive Utility The first section of the book gives you a summary of the main types of compressors (reciprocating, rotary screw, centrifugal). It also introduces how to calculate the cost of your compressed air, and the topic of how to recover energy expenses.
Section 2: Compressed Air Drying This section provides the facts about dew point, and the sources of moisture. You will find information on the different types of compressed air dryers including tips on how to select the most cost effective dryer for your application.
Section 3: Supply Side Air Treatment The various filters in a compressed air system are discussed in this section. The type of filtration has an impact on the amount of energy wasted before the compressed air makes it to the process.
Section 4: Condensate Drains This section describes the pros and cons of the different types of drains on the market. It also describes some of the common installation mistakes discovered during air audits.
Section 5: Demand Side Distribution The proper design and installation of the air piping system can lower the annual energy cost of a facility. It can also reduce the maintenance of the system when done right. This section gives the details on air piping system.
Section 6: Practical Use of Storage This section explains how to avoid wasting energy, and creating problems, when storing compressed air.
Section 7: Other Common Air System Operations That Create Opportunities This section uses case studies to illustrate how to avoid problems, and how to lower your energy costs.
Section 8: Compressed Air Savings Opportunities in the Air Using Side This section provides the true energy cost of using compressed air instead of alternative utilities.
Section 9: Flow Measurement It is helpful to know the air flow in CFM to trouble shoot a problem or to determine if more compressors are needed in a plant. However, there are many instances each year when decisions are made based on incorrect or misinterpreted data taken from flow meters. This section provides details on the operation of the main types of flow meters.
Section 10: Ask The Experts This chapter covers some of the most interesting questions received by the author. The questions illustrate how often customers are given poor information from vendors in the compressor industry. And, the answers provide insight on a variety of topics.
Section 11: Terminology & Technical Support The final section gives you a summary of terms and more than 30 charts on issues relating to compressed air. This information is a resource that can be referred to for years to come.
About the AuthorThis book is published by the author, Hank Van Ormer, who also wrote the majority of the articles. Mr. Van Ormer has been associated with the Compressed Air and Gas Business and its allied industries for almost 40 years. While attending Gettysburg College he worked summers in the research and development department of a rotary and reciprocating compressor manufacturer. After graduation in 1959, he began full time work with them and handled various areas of Industrial and Construction Equipment product development, marketing and sales. Over the years, he has worked with several leading manufacturers in similar areas with particular emphasis on rotary and centrifugal compressors. In 1986, Mr. Van Ormer started his own independent consultant company, Air Power USA, Inc. which specializes in Air Compressors, Compressed Air Equipment and Compressed Air Systems for the industrial and construction markets. Mr. Van Ormer has developed several accredited training courses for continuing education and complete curriculum or technical colleges. Air Power USA offers complete plant surveys and problem solving analysis of compressed air systems including energy management studies. The last several years, Mr. Van Ormer has been very active in the Department of Energy “Compressed Air Challenge Program”. As a charter member of the Compressed Air Efficiency council, he worked with the basic program development and was a member of the Training Committee. In December of 1998, Mr. Van Ormer was selected as one of “Twelve Core Trainers” from applicants all over the United States. Free Newsletter
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your subscription data confidential. “Energy Savings in Compressed Air Systems” can save you thousands of dollars each year, and can help you get more from your air system. This 260 page book was assembled to share the details of energy savings available in the demand side of a compressed air system. The text is easy to understand with charts, graphs and photos that illustrate the topics. It is a hardcover book with 8-1/2” x 11” size pages. The book is $85 US each with Free Shipping. Order today and start benefiting from this resource. Ordering with a Credit Card
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