A New Approach for Determining Optimal Air Compressor Location in A Manufacturing Facility to Increase Energy Efficiency

Abstract

An approach is proposed to determine the optimal air compressor location in a manufacturing facility. The optimization strategy is based on an objective function that minimizes the total energy consumption of the air compressor -thereby decreasing the energy cost -in the manufacturing facility. Compressor distance to air demand, air pressure, load factor and volume are all factors considered in the model. The proposed model determines the facility's attributes based on user inputs of facility size. The model then divides the facility into zones and creates a zone-to-zone distance matrix within the prescribed facility. Demand and pressure profiles of the facility are created based on the equipment and tools present in each zone. The model also determines the ideal air compressor horsepower required to meet the facility air demand at the required pressure. Air pressure drops are incorporated using a compressed air pipeline pressure drop table, while air leaks are calculated throughout the system using novel and conservative estimation technique. Facility shape and facility temperature profile used to ensure safe and proper operation of the air compressor are also considered in the objective function.