Air compressors support many industries, from small auto shops powered by reciprocating compressors to large-scale vertically integrated textile units powered by high volume centrifugal compressors.
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Air compressor technology is simple. Powered pistons, screws or impellers compress a volume of atmospheric air to a required pressure for an application. The design and use of compressed air systems have evolved to suit varying industry needs.
Over time, manufacturers have invested in technology to overcome air compressor inefficiencies and to simplify the user experience. However, compressed air remains a major utility expense.
Image 1 shows the typical life cycle cost breakdown of a compressor. Power consumption accounts for nearly 88 percent of a compressor&#;s 10-year life span cost. Up to 50 percent of air is wasted, resulting in thousands of dollars lost in energy, according to the United States Department of Energy (DOE). There are many factors that contribute to an inefficient operation.
Here are three main points to evaluate to transform utility cost into an energy-saving opportunity.
Bigger is not better when it comes to air compressors. A rotary screw compressor is most efficient when running in a 100 percent loaded condition. (Loaded, means the compressor is producing air; while unloaded means the compressor remains idle.) A compressor will continuously load when its air production capacity matches the air requirement. For example, if a compressor produces 500 cubic feet per minute (CFM) but the air requirement is only 300 CFM, then the compressor will be in unload condition for a significant portion of the time.
Screw compressors are inefficient in the unload condition and, thus, a larger compressor will use more energy and consumables than a right-sized compressor for a given air requirement.
As a general rule of thumb, a compressor that is only running at 50 percent capacity will consume 20 percent or more power than a compressor that is running at or close to full capacity.
Determining the right size can be sufficient to improve energy efficiency, but what about those customers who have varying demand patterns during the day or those customers who anticipate an increase in manufacturing capacity requiring more air? Variable frequency drives (VFDs) provide solutions to both situations.
A VFD works by reducing the compressor motor&#;s speed to lower flow to match the actual air demand of the customer. By reducing the motor&#;s speed, the compressor consumes less energy than a fixed speed compressor versus inlet modulation control or load/no load (at 3 gallons per CFM storage). Image 2 illustrates the power savings with a VFD.
When looking to improve energy efficiency, customers have to look further than the air compressor and evaluate the compressed air system as a whole. The biggest area for improvement could be the facility&#;s distribution system&#;how the compressed air is transported and used in the end application. Both the design of the distribution and material used for piping affect energy efficiency.
When designing a compressed air piping system, the shorter the distance from the compressor to the application, the better.
Minimizing bends en route to the application reduces pressure drops and improves the efficiency of the system.
Image 3 compares an inefficient line design versus an efficient design. Many vendors may not be able to provide sweeping elbows that minimize pressure drop, so for practical purposes, if a vendor can only provide 90 degrees of piping, consider upsizing the pipe diameter by 1 inch to minimize pressure drops.
Choosing the material for the distribution system is as important. Plastic, aluminum and steel are the most common materials for compressed air piping. While steel is more accessible than aluminum, aluminum offers lower weight and corrosion resistance. Compressed air contains trace amounts of oil and water, which can cause line corrosion and, in turn, results in pressure drops and affects efficiency.
In addition, compressed air lines are dynamic in that they are constantly vibrating owing to the passage of compressed air.
Over time, these movements weaken joints and can result in leaks. Leaks found in a facility&#;s air compressor system can waste up to 25 percent of compressed air costing, thousands of dollars in electricity per year.
Air audits determine the actual air demand and evaluate the efficiency of use of compressed air in an operation. Air audits can determine the appropriate size needed, evaluate the need for a VFD, identify inefficiencies in piping design and ultimately optimize usage.
Compressor manufacturers and compressed air experts are capable of conducting air audits. An air audit expert will use data loggers, flow meters and leak detection devices to evaluate an operation&#;s air usage.
Typically, the auditor will spend days gathering data to fully understand the varying demand conditions and the nature of use. Following the analysis, they will issue a report with a summary of the potential savings along with recommended changes and associated costs.
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Image 4 is an example of a summary air audit report that shows a textile operation&#;s before and after energy cost following an air audit.
When it comes to powering your industrial operations, choosing the right air compressor is crucial. With various types of industrial air compressors available, it can be challenging to determine which one is the best fit for your business. The type of compressor you choose will directly impact efficiency, energy consumption, and overall productivity.
By understanding the differences between common industrial air compressors, you can select the one that best aligns with your operational requirements, ensuring that your investment delivers optimal performance. You can be sure that you&#;ll have the right one for your industry and your business.
A rotary screw air compressor works through two internal screws rotating in opposite directions. This traps and compresses air between them. Rotary screw compressors come equipped with an internal cooling system and require a low level of maintenance. They are used across a wide range of applications in industrial work. They can be used for continuous work, because of their internal cooling system.
Rotary screw air compressors can be lubricated with oil, or used oil free, depending on the needs of the application. They are an excellent choice when large volumes of compressed air are necessary, such as for larger tools.
Rotary screw compressors are commonly used in:
Reciprocating air compressors use pistons controlled by a crankshaft to achieve high pressure. As air or gas enters the device, it&#;s driven in a reciprocated motion via the crankshaft and then discharged from the device. Reciprocating air compressors commonly achieve up to 5,000 PSIG pressures.
These compressors are commonly used in oil refineries, gas pipelines, offshore platforms, or refrigeration plants. Reciprocating air compressors are ideal in situations that require high pressure.
Reciprocating compressors are commonly used in:
Rotary Vane air compressors became a popular choice because they can produce high volumes of compressed air without expending much energy. They are another ideal choice for businesses that require a high volume of compressed air with reduced energy costs. They have less downtime and more productivity for your business. Rotary vane compressors are compact and engineered to meet exacting specifications.
Rotary screw compressors are commonly used in:
A rotary scroll air compressor uses two spiral-shaped scrolls with one fixed, and one moving in an orbit to compress air. As the air is compressed it is discharged through a port in the housing. This compressor has a continuous and smooth process with very little vibration.
A rotary scroll compressor works well when a steady flow of compressed air is needed. Some typical industries that use rotary scroll compressors include electronics manufacturing, medical equipment, and food and beverage. They are an efficient and reliable choice.
Rotary scroll compressors are commonly used in:
The main difference between these compressors is the lubrication, sealing, and cooling of components in the machine as it&#;s working. Oil-lubricated compressors have oil in the compression chamber to cool the compressor and increase its efficiency.
Oil-free compressors only use oil to lubricate bearings and gears, but the oil does not come near the compressed air flow. This means that the compressed air is free from any oil contamination, a valuable feature for many industrial processes.
Oil-less compressors do not use any oil within the compressor whatsoever. The bearings are permanently lubricated so they do not rely on an external lubricant.
Oil-free compressors are commonly used in:
Air compressors are a vital part of industrial production and the backbone of your business. It&#;s important to select a compressor that streamlines efficiency and keeps your energy use optimized.
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