Compressed Air 101: Getting Compressed Air to Work

Abstract

"Air compressors are a significant industrial energy user. Based on a survey (conducted by Oregon State University and the Bonneville Power Administration) of energy audit reports from 125 plants, air compressors account for roughly 10% of total plant energy use. Furthermore, air compression is inefficient with up to 95% of compressor power dissipated as heat. Thus even minor improvements in system operation, control strategies, and efficiency can yield large energy savings and significant non-energy or productivity benefits from reliable compressed air.

Compressed air is often called the ""fourth utility"" in industrial facilities after electricity, natural gas, and water. It provides motive power for machinery, cooling, materials handling, and hand tools. It is a safe, flexible, and powerful resource, but one that is seldom run for low operating costs or best productivity.

Learning the basics of compressed air systems represents the beginning of both reducing energy costs and enjoying the productive benefits of reliable compressed air. Compressed air management systems, including a system approach to managing demand, stabilizing pressure, reducing leaks and compressor controls, can allow the industrial end user to save 20% - 50% of their air compressor electricity usage.

The monitoring capabilities of compressed air management systems provide a useful tool through power, pressure and flow trending to maintain both the energy savings and increased system reliability. More efficiently managed compressed air systems are less costly to maintain and have less impact on the environment.

The most important issues of industrial compressed air in relation to energy efficiency and management are: 1. Compressed air is an essential industrial utility; 2. Compressing air is a fundamentally inefficient energy transformation process; 3. Optimal operation of compressed air systems in industrial plants is seldom a priority and adequate management infonnation is rare, resulting in negative impacts on production and even less efficiency."