Compressed Air System Energy Efficiency

Measure Information Sheet

May 2006

Compressed air is often called the "fourth utility," after electricity, natural gas and water. For
many businesses, compressed air is a vital input to their production process. However, too often,
compressed air systems are highly inefficient, resulting in significant wasted energy (and cost).
 Is compressed air free?
No, compressed air is not free. Although "it's only air," compressed air is actually very
expensive because only 10 to 20 percent of the electric energy input reaches the point of
end-use. The remaining input energy converts to wasted heat or is lost through leakage.
For example, to generate 5 CFM it takes 1 HP!

 What are some ways I can reduce my compressed air costs?

There are many ways that your company can reduce its compressed air costs by making
the compressed air system more energy efficient. Below are several “best practices” that
companies can apply to reduce their compressed air costs.

1) DETECT AND REPAIR LEAKS. Leaks in an industrial compressed air system can waste
significant amounts of energy, as much as 20 to 30 percent of compressor output. Detection and
repair can reduce leaks to less than 10 percent of compressor volume. Leak repair, when
combined with adjustments to compressor controls, can reduce compressor run time, increase
equipment life and reduce maintenance. However, without appropriate compressor controls,
there may not be much energy savings. Repairing leaks also reduces demand for new compressor
capacity by reducing wasted air. While leakage may come from any part of the system, the most
common problem areas are couplings, pressure regulators, condensate traps, shut-off valves and
pipe joints.

2) ELIMINATE INAPPROPRIATE AND UNNECESSARY USES. Compressed air generation is

one of the most expensive auxiliary processes for an industrial facility. Over 80 percent of the
electricity used for this process is attributed to wasted heat at the compressor. Consider more cost
effective ways to accomplish the same tasks. If air nozzles are required, a Venturi type nozzle can
significantly reduce compressed air demand, as well as lower noise levels. If an air motor is used
for mixing, consider replacing with an electric motor. Also check to make sure that air is not
being supplied to unused or abandoned equipment. Also, many lumber mills use compressed air
to charge the fire protection system. If the mill is not is not running 3 shifts, consider using a
smaller air compressor.

3) MINIMIZE PRESSURE DROP. Pressure drop is the reduction in air pressure from the
compressor to the actual point of use. A properly designed system should have a pressure drop of
below 10 percent of the compressor's discharge pressure. Systems are frequently operated at
higher pressures than necessary to compensate for unnecessary pressure drops, which waste
energy and money. The most frequent problem areas are after-coolers, separators, dryers, filters,
regulators and poor connection practices at the point of use. For systems in the 100 pounds per-
square-inch-gauge (psig) range, every 2 pounds per-square-inch (psi) increase in discharge
pressure will increase energy consumption by about 1 percent at full load.

Page 1 of 3 CA06-Form 3
 4) REDUCE SYSTEM PRESSURE. Many plant air compressors operate with a full load
discharge pressure of 100 psig and an unload discharge pressure of 110 psig or higher. The actual
pressure requirements of machinery and tools are often 80 to 90 psig or lower. Reducing and
controlling system pressure downstream of the primary receiver can reduce energy consumption,
leakage, demand for new capacity, as well as cause less stress on components and operating
equipment. Be cautious when lowering system pressure because large changes in demand can
cause the pressure at points-of-use to fall below minimum requirements. You can avoid this by
carefully matching system components, controls and storage. Address unnecessary pressure
drops prior to lowering system pressure.

In some plants, the high pressure requirements of a few uses drive the pressure
requirements for the entire system. If these uses can be supplied by a dedicated
compressor, the rest of the system can operate effectively at a lower pressure.

5) SIZE AND CONTROL COMPRESSORS TO MATCH LOADS. Since compressor systems

are typically sized to meet a system's maximum anticipated demand, a control system is often
required to reduce output for low demand periods. The compressor package usually includes
controls. For systems with multiple compressors, it is usually good practice to follow a base-
load/trim strategy. This allows some compressors to be fully loaded to meet the base-load
demand. The compressor(s) with the highest part-load efficiency is placed in trim service to
handle variations in load. This strategy requires controls that operate the group of compressors as
an integrated whole. This is typically far more efficient than placing compressors in modulation,
which is a common practice.

An effective control strategy includes adequate storage. Employ storage to cover peak air
demands by reducing both the amount of pressure drop and the rate of pressure decay by
locating receivers near surge demands. For systems with highly variable air demand,
achieve tight control by combining storage with a pressure/flow controller. Narrowing
the pressure variation with better controls uses less energy and minimizes potential
negative effects on product quality.

6) USE EFFICIENT PART-LOAD CONTROLS. For rotary screw compressors, throttling the air
can allow the output of a compressor to meet flow requirements. Throttling is usually
accomplished by closing down the inlet valve, which restricts inlet air to the compressor.
However, this control scheme is inefficient for controlling compressor output for displacement
compressors. Most manufacturers offer control options for larger compressors that are more
efficient at part loads. Load/unload controls can improve the efficiency at part-load operation if
there is enough storage capacity. Another efficient approach uses variable displacement control
or variable capacity control, which reduces the effective length of the rotors at part loads.
Variable speed control can be a very efficient approach to provide "trim" duty. Proper selection
of part-load controls depends on specific compressed air system requirements.

7) OPTIMIZE DISTRIBUTION SYSTEM OPERATION. The air distribution system that

connects major compressed air system components is very important. Appropriate sizing and
layout will ensure proper air supply, good tool performance and optimal production. Size and
arrange the complete drying, filtration and distribution system so that the total pressure drop from
the air compressor to the points of use is below 10 percent of the compressor discharge pressure.
Choose equipment and piping components to avoid excessive pressure drops and leakage. You
may also dramatically improve the operation of existing systems by replacing worn out or
inadequately sized hoses and couplings, inspecting and maintaining filter/regulator/lubricator
components and installing adequate storage.

Page 2 of 3
 8) USE OUTSIDE AIR INTAKE WHEN OUTSIDE AIR IS COOLER THAN INSIDE AIR.
Compressor work increases proportionally as inlet air temperature increases. Cooler air is denser
and provides more mass for each compression cycle with no additional power use. Lower inlet air
temperature will result in less compressor work. Use outside air for cooling reciprocating and
lubricant-free screw compressors when it is cooler than indoor air. Locate compressors so
radiator stays clean and free of oil, saw dust and debris. This may also help keep the compressor
cool.

9) IMPROVE ROUTINE MAINTENANCE. Inadequate compressor maintenance can increase

energy consumption significantly via lower compression efficiency, air leakage, pressure
variability, higher operating temperatures, poor moisture control and poor air quality. Keep
radiators clean and clear of oil and sawdust to keep air and oil cool. This can add up to thousands
of dollars every year. Inspect and adjust controls periodically to ensure that they are operating
properly and at appropriate settings for system requirements. For basic maintenance, inspect and
clean inlet filters, drain traps, maintain lubricant levels, condition belts, maintain operating
temperature, inspect air line filters and check water cooling systems.

10) RECOVER WASTE HEAT. As much as 80 to 93 percent of the electric energy drawn by an
industrial air compressor is wasted as heat. Properly designed heat recovery can recover 50 to 90
percent of the waste heat and use it to heat air or water. Common applications include
supplemental space heating, industrial process heating, water heating, makeup air heating and
boiler makeup water preheating. Heat recovery systems may also help facilities address negative
plant pressure concerns. While most compressed air systems do not take advantage of heat
recovery, the paybacks can be less than one year.
 Now I’m interested in taking the next steps to make my compressed air
system more energy efficient. How do I get started?
Different types of assistance may be available through your serving utility. Contact your
utility account representative today!

NOTE: This information was adapted from the “BestPractices for Compressed Air Systems,” 2003

The Compressed Air Challenge (CAC) is a nationwide government/industry collaborative formed in 1997. The
goals of the CAC are to raise awareness in industry to the true costs and efficiency improvement opportunities in compressed air systems
operations and to bring compressed air best practices to the plant floor level for American manufacturing. Contact us toll free at 866-442-
4247or www.compressedairchallenge.org for more information

Page 3 of 3