Compressed Air System Analysis and Retrofit for Energy Savings

Abstract

This case study paper describes energy efficiency improvements to a large sanitary paper products manufacturing facility that underwent a comprehensive compressed air system retrofit. The project was motivated by potential energy savings and better system performance, resulting in improved system reliability, reduced energy consumed by over 240,000 kWh annually, reduced maintenance cost by nearly $7,000 annually, and reduced electric utility bills by nearly $19,000 annually (a 17% savings). This project used a whole-system approach to evaluate both the supply and demand sides of the system to develop the most comprehensive and cost effective solution for providing high-quality compressed air to the manufacturing processes. The project included several actions including piping retrofits, equipment upgrades, pressure control changes, and compressor retrofits.