Compressed Air System
Optimization Rebate
11/1/2010
2010 Kaeser Compressors, Inc., USA (V1.0)
Huge Potential for Savings
In many plants, compressors
use more energy than any
other type of equipment
Many plants can realize energy
savings of 20 to 50% while
improving system performance
Sources of waste:
• Leaks
• Pressure drop
• Artificial demand
• Inefficient controls
• Inefficient compressors
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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Methods of Increasing Energy Efficiency
Average
Total
Possible Steps to Increase Your Energy Efficiency
Applicability Potential
Potential
%
Savings % Savings %
Use high efficient drives
25
2
0.5
Use compressors with modern speed controls
25
15
3.8
Update your compressor
30
7
2.1
Use heat recovery
20
20
4
Improvement of cooling, drying, and filtration
10
5
0.5
Optimize the system (multi-pressure systems)
50
9
4.5
Minimize the pressure drops within the system
50
3
1.5
Optimize the consumer system operation and maintenance
5
40
2
Minimize leakage
80
20
16
Change filters regularly
40
2
0.8
*article from the VDMA Nachrichten
Cumulative potential savings 35.7%
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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ZERO LOSS CONDENSATE
DRAIN
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4
Automatic Magnetic Drain (AMD)
AMD 6550
AMD 1550
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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5
Automatic Magnetic Drain Traps
AMD 6550 Drain Operation
Opposing
magnets
Working
cylinder
3/8” ball
valve
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6
Eco-Drain Series
Eco-Drain 14
Eco-Drain 12
Eco-Drain 30
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Eco-Drain 13
Eco-Drain 31
7
7
Eco-Drain Series Drain Traps
Eco-Drain Operation
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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8
MASTER CONTROLLER
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% of Full Load Input kW Required
Part Load Energy Consumption
80
60
Upper Range
Modulation
Turn Valve
Turn Valve with
Vented Sump
40
20
Energy Savings
0
20
40
60
80
100
% of Full Load Capacity
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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Sample 1 –
SFC 110, 2x CSD 75 and SAM
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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Sample 1 – Sample Day
CSD 75T base loaded the entire day. SFC 110
trims as necessary maintaining +/- 1 psi within
the system.
Averaged over 10 seconds.
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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Sample 1 – SAC Plus February 2008 Sample Week Energy Cost Table
(SAM Controlling System)
Flow Profile of Sample Week
2162859
Duty cycle of all three
units almost 100%,
which results in the
lowest possible Idle
Power Cost.
Corrected Specific Power,
flow was entered incorrectly
originally in SAM
SFC 110
CSD 75T
CSD 75T
Total CF
Total kWh
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
Specific Power (kW/CFM)
Specific Power (kW/100 CFM)
Sample WeekCubic Foot
As-recorded in SAC Plus
3,278,548.00
846,336.00
84,918.00
4,209,802.00
17,514.00
Sample Week Cubic Foot
Corrected
3,278,548.00
2,162,858.67
217,012.67
5,658,419.33
17,514.00
0.250
25.0
0.186
18.6
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Sample 1 – SAC Plus April 2008 Energy Cost Table
(SAM not Controlling System)
Pressure fluctuations from 115psig
Duty cycle of all three units
not 100%, so additional
savings can be achieved
SAM in Manual Mode
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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CYCLING DRYER
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COMPRESSED AIR
EFFICIENCY STUDY
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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Compressed Air Efficiency Study

Key differences from typical energy audits
–
Short sample interval necessary to capture
compressed air demand events
– kW and kWh tell only a small part of the system
performance
– Should include an analysis of wasted air
–
–
Leaks
Inappropriate uses
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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Leakage Losses
Hole Diameter
1/16”
1/8”
1/4”
Cost Per Year
$ 820
$ 3,285
$ 13,133
Based on $0.08/kWh, constant
operation and 100 psig
This small hole
(1/4" diameter)
costs you approx.
$1,095
every month
© 2010 Kaeser Compressor, Inc., USA / V1.7 / www.kaeser.com
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