Energy

Conservation
in

Air Compressors &

Compressed Air System
Confederation Of Indian Industry
Energy Management Cell

Life Cycle Cost For A

Compressor

Initial Cost Maintenance

5%
Cost
5%

Energy Cost
90%

Sankey Diagram for Compressed Air

System

Air Compressors
Positive Displacement
Type
Reciprocating

Rotary

Vertical Type

Screw
(high speed)

(100-500 cfm)
Horizontal
Balance
Opposed
(200-5000 cfm)

Advantage: Intake
air can also have
some moisture
Disadvantage: Oil
carry over

Centrifugal
Type
Radial
Flow

Axial
Flow

> 12000 cfm

Single Acting, Two Stage

*Filter
Reciprocating Compressor
Inlet filter
Inter cooler

Motor

After cooler

Valve

Motor starter

Dryer

Relief
valve
Trap
(Drain)

Pressure
switch
Receiver

Trap
(Drain)

Trap
(Drain)

Why Inter-cooler?
Compressed air leaves cylinder at high
temperature
Density is lower
Volumetric decreases
Inter cooling reduces temperature &
volume
Mass of air delivered increases
Inter-cooler generally saves 7 %

Why After-Cooler?
How much is the energy savings?
A) Savings same as inter cooler - 7 %
b) Higher than inter cooler
c) Lesser than inter cooler

Why After-Cooler?
How much is the energy
savings?

At higher temperature moisture carry

over very high
Condensed water moves with same
velocity of air
Damage to instrument valves
Makes instruments sluggish

After-cooler saves energy higher

when air dryers are installed

Methodology for Energy Audit

Is the correct type and size of
compressor being used?
Is the system efficient?
What is the required operating
pressure?
What is pressure drop between user
and compressor?

Methodology for Energy Audit

Is compressor cooling water
monitored?
Are auto drain valves provided?
Can compressed air be substituted?
Are valves provided at the user
points?

Norms
Volume of the receiver
1/10th of flow rate in m3/min to 1/6th of
flow rate in m3/min
Velocity of air in a compressed air pipe
line
Between 6 and 10 m/sec

Norms
Water consumption
350 LPM for 1000 CFM @ 7.0 kg/cm2
Pressure drop in a pipe line
In 800 m length pipe line, pressure
drop should not be more than 0.3
kg/cm2

Terminology
Pressure
Load Pressure
Unload Pressure
Power
Load Power
Unload Power

Optimal Utilisation of
BackgroundCompressors
37 kW compressor in
operation
At present loading 30%
Unloading - 70%
Power consumption
Unload - 9 kW
Loading - 27 kW

Install 15 kW ON/OFF Air Compressor and

Use Existing 37 kW Air Compressor as
Standby
Action
Install 15 KW package air
compressor
Saves no-load power
Use existing compressor as standby

Rs.

Rs.

Savings - Rs.59,000
Investment Rs.50,000
Payback - 11 months

Manage Available Facility

Optimally
Instrument Air
Compressor
(6.5 bar, 570
cfm)

Refrigerated
Receiver

type
dryer

Average loading:60%
Load power
: 85.2 kW
Unload power
: 43.5 kW

Brine Air
Compressor
(6.5 bar, 210
cfm)

Receiver

Average loading: 55%

Load power
: 33.7 kW
Unload power
: 15.3 kW

Manage Available Facility

Optimally
Interconnect the two receivers
Stop Brine compressor
Annual Savings
lakhs
Investment
Payback period
month

: Rs.4.28
: Rs.0.02
:<1

Optimizing Generating Pressure

of Air Compressors
Compressor operating power is directly
proportional to operating pressure
Compressed air applications & pressure
requirements
Bag filter
5 bar
Instrument Air
5 bar
Air Blaster
5 bar

Optimizing Generating Pressure of

Air Compressors
Compress Loading Unloading Avg Pr.
or
Pr
Pr
(Bar)
#2
6.2
6.9
6.55
#3
6.2
6.9
6.55
#4
6.2
6.9
6.55
#5
6.2
6.8
6.50
Many plants are operating at
generating pressure of 5.5 bar

Optimizing Generating Pressure of

Air Compressors
PRVs used to regulate the pressure at the
user end
Main bag house
Packer 1, 2 & 3 bag filters
Indicates the pressure requirement at the
user point is lesser than the generation
point
Valves provided on main lines
Loss of pressure is 0.5 to 1 bar
10-15% saving potential

Optimizing Generating Pressure of

Air Compressors
Action taken :
Opened all PRVs in the circuit
Results in increase in pressure at the
user point
Reduced the pressure setting of the
compressors
Average generation pressure at 5.8
bar as an initial step
Loading
@ 5.5 bar
Unloading@ 6.0 bar

Optimizing Generating Pressure of

Air Compressors

Annual Saving -

Rs 25.00 Lakhs

Investment

Nil

Optimize the Pressure Setting of

RM Pulsejet Bag Filter
Raw mill bag house specification
Compressed air requirement : 352
CFM
Pressure requirement : 4 - 5 bar
Compressed air from common header
Pressure at the bag house is maintained
at 6 bar

Optimize the Pressure Setting of

RM Pulsejet Bag Filter
High pressure at the bag house results
in
Higher
power
consumption
of
compressors
Reduces the life of the bag
Many plants has installed separate
compressor for pulse jet bag filter
operation maintaining pressure at 4.5
bar

Optimize the Pressure Setting of

RM Pulsejet Bag Filter
Installed new small capacity compressor
of 380 CFM
compressed air pressure maintained at 5
bar
21 % savings achieved
Annual Saving
Investment
Payback period

Rs. 8.00 Lakhs

Rs. 8.25 Lakhs
12 months

Utilise the Correct Type of

Compressor

Battery of screw & reciprocating

compressors 200 kW capacity
2 Screw Compressors
One 100% Load
Second 40% Load

Reciprocating compressor
stand by

Screw compressor operation

Load power = 180 kW (40%)
Unload power
= 60 kW (60 %)

Utilise the Correct Type of

Compressor
Reciprocating Compressor
Operation
Load power

= 165 kW (40%)

Unload power

= 25 kW (60%)

Operate Reciprocating
Compressor on continuous basis
Keep Screw as stand by

Annual Savings = Rs. 4.90

Lakhs

Capacity Test (Pumping

Method)

P2 - P 1
1
Average Compressor Delivery =
. VR .
P
t
P1 = Initial pressure in receiver
P2 = Final pressure in receiver
P

= Atmospheric pressure

VR = Volume of air receiver

t = Time taken for charging the receiver
from P1 to P2

Operation of compressors
5 compressors available
660 CFM, 7.5 bar, 110 kW
3 compressors are required to be
operated

Operation of Compressors
No
CP1
CP2
CP3
CP4
CP5

Operation of Compressors
No

kW

CP1

110

CP2

90

CP3

100

CP4

105

CP5

95

Operation of Compressors
No

kW

FAD

CP1

110

660

CP2

90

500

CP3

100

600

CP4

105

645

CP5

95

470

Operation of Compressors
No

kW

FAD

kW / CFM

CP1

110

660

0.17

CP2

90

500

0.18

CP3

100

600

0.17

CP4

105

645

0.16

CP5

95

470

0.20

Comparison of Specific Power

Consumption

Reciprocating Centrifugal
FAD

Screw

112 m / min (3950 cfm)

KW

549

521

650

Specific Power
3
(kW/ m / min)

4.9

4.65

5.8

Replacement of Inefficient
Compressors
Compressor Pneumatic Conveying
Design Specifications
Capacity (FAD) = 20 m3/min
Pressure

= 7.0 kg/cm2

Motor

= 120 kW

10 year Old Compressor

Re-boring carried out
Overhauling done

Replacement of Inefficient
Compressors
Capacity Test Conducted
Actual volume (FAD)

= 14.6 m3/min

Volumetric Efficiency = 73%

Operating Pressure
Specific Power

= 7.0 ksc

= 6.56 kW per m3/min

Specific Power Norm - 4.9 kW/m3/min for 7.0

ksc

Replacement of Inefficient
Compressors
Energy Saving potential : 25%
Replaced with New Reciprocating
Compressor
Annual savings = Rs. 4.03 Lakhs
Investment
= Rs.8.00 Lakhs
Payback period = 24 months

Improve the Performance of

Compressors
Capacity test conducted by pump
up method
Rated

Operating Parameters
Pressure

Compresso
r

Norm
CFM

CFM

(bar)

kW

kW/CFM

#2

1287

912

6.55

229

0.25

0.17

#3

1287

910

6.55

230

0.25

0.17

#4

1287

995

6.55

205

0.20

0.17

#5

1287

948

6.50

216

0.22

0.17

Improve the Performance of

Compressors

Compressors operates at higher SEC wrt

the norm of 0.17kW/CFM at 6.5 bar
pressure
0.07kW/CFM more than the norm
Replaced with new energy efficient
compressor
Achieved 28 % savings

Improve the Performance of

Compressors

Annual Saving -

Rs 30.57 Lakhs*

Investment

Rs 26.00 Lakhs

Payback

10 Months

*Savings for one compressor replacement

Segregating LP & HP users

4 compressor installed in CPP 25 MW
3 Nos 660 CFM & one 680 CFM

3 compressors in operation
All compressors
header

connected

660CFM

660CFM

3
660CFM

in

4
680CFM

common

Optimize the Operation of CPP

Compressors
Compressor catering air for
Instrument air application ( < 30%)
Ash conveying
ESP to intermediate hopper
Compressors operate at generating pressure of
6.5 bar
Ash conveying air pressure is regulated by PRV
Pressure after PRV is 4 bar
Results in pressure loss (38%) across the
PRV

Optimize the Operation of CPP

Compressors
Segregated LP user by dedicating 2
compressors for ash conveying
Operate the compressor at 4.25
bar pressure

Loading
@ 4.0 bar
Unloading @ 4.5 bar
Annual Saving -

Rs 14.00 Lakhs

Investment

Nil

VFD - A New Concept

Advantages
Operates at Lower Avg. Pressure
Proportional Savings
No Unloading
Less Leakages
Lower Pressure
Better Motor Efficiency

Concept - Conventional Control

P
r
e 7.0
s
s
u
r 6.5
e
6.0
Ksc

Upper Limit
Average Pr.

Lower Limit

Time

Reqd. Pr.

Concept - VFD Control

P
r
e
s
s
u
r
e
Ksc
6.5
6.1
6.0

Savings Due
to Pressure
Reduction

With VFD
Reqd. Pr.

Time

Savings in Unload Power

Compressors Designed
to meet Fluctuating
Load

1500
C
F 1400
M

Fluctuating Load Leads

to Load / Unload

1300
R
e
q
1200
d

Lean Time - Unload

Unload power 15 - 40%

1100
0

12

Time

24

No useful work
VSD Avoids Unloading
of Compressors

Case Study
PIC

6.0 KSC to 7.0 KSC

M
Compressor 1

VSD

Power In

Users

Receiver

M
Compressor 2

M
Compressor 3

M
Compressor 4

4 Compressors in
Operation

Install VFD for One Compressor

VFD For One Compressor

Constant Pressure of 6.0 ksc
4% Savings in all
compressors
Annual Savings
= Rs.12.00
Lakhs
Investment
= Rs. 12.00
Lakhs
Payback period = 12 Months

Optimizing System Pressure

6.2 bar 5.7 bar

Dryer

To Plant
Common Header

6.3 bar

To Plant

#1

#2

#3

Loading Pressure
- 6.0 bar
Unloading Pressure - 6.5 bar

User Point
5.7 bar

Optimizing System Pressure

Pressure drop across the generation point and
common header was measured to be 0.6 bar
Dryer and filter is installed in between
compressor and common header
Pressure drop across dryer 0.1 bar
Pressure drop across filter 0.5 bar
Design pressure drop across filter 0.1 bar

Optimizing System Pressure

Around 0.4 bar pressure is being dropped excess
in the filter
During audit the dryer was not in operation
however the air is being passed through the
dryer
Results in additional 0.1 bar pressure drop
In-effect total 0.5 bar is lost across the dryer and
filter system
6.6% Power loss across filter and dryer

Optimizing System Pressure

Replaced filter & Bypassed dryer
Reduced the pressure setting of the compressor
Loading @ 5.5 bar
Unloading @ 5.8 bar

Annual Saving -

Rs 2.20 Lakhs

Investment

Nil

Minimise Leakages
Common in all
industries
Tricky
Quantification

God has given abundant air, which is

free!!
But compressed air is not free!!

Quantification
Allow compressor to run normally
Allow compressed air to flow in the
system
Close all the user points
Measure the loading and unloading
time
Percentage of loading time is
percentage of leakages

Leakage Test
Close all user points
Charge the lines
Note: On-load time of compressor (T)
Off-load time of compressor (t)
Q : Capacity of compressor

Air leakage : L

T
T+t

.Q

Air leakage
% air leakage
=
x 100
Compressor capacity

Cost Of Leakage At 7kg/cm2

Power
Orifice dia Air Leakage
Annual Savings
Wasted
(mm)
(cfm)
@ Rs.3.50/kWh.
(kW)
1.6
6.5
1.26
Rs.35,000
3.2
26.0
5.04
Rs.1,40,000
6.4
104.0
20.19 Rs.4,25,000

Minimize Compressed Air Leakage &

Avoid Unwanted Use of Compressed Air
Fly ash unloading compressor
Quantity of Leakage : 22%
Cylinder air seals
Raw mill compressor
Quantity of Leakage : 25%
Cylinder air seals

Minimize Compressed Air Leakage &

Avoid Unwanted Use of Compressed Air
Recommendation

Arrest all the cylinder air seals for both

the compressors

Annual Saving -

Rs 6.00 Lakhs

Investment

Rs 1.00 Lakhs

Simple payback -

2 months

Use Transvector Nozzle In Air Hose

Sucks atmospheric air along with air jet
Reduces air consumption by 50%

Compressed air used for cleaning the burrs

Provided transvector nozzles at the end users
Atmospheric
Air

Atmospheric
Air

Compressed Air
@ 7.0 KSC

Replace compressor air with

Blower for Cleaning
Capacity of the blower
Flow : 5 m3/hr
Pressure : 500 mmwc
Power : 200 W
Annual Saving
Investment
Payback

Rs. 0.59 Lakhs

Rs. 0.60 Lakhs
13 months

Optimize the Auto Drain Valve

operation
Compressors will operate with dryers
In a plant
Humidity levels are observed between 35-45
%
Auto drain valve is operating for 8sec purging
for every 2 min
Frequent draining will results in
Leakage of more compressed air
Purging time interval has to be decided based on
season and humidity levels
Level based sensors is one more option

Audit Approach
Step 1 : Metering
Dedicated meters section wise
Integration with EMS / Online
display
Provisions for capacity test /
flow meters
Pressure measurements at
different locations (Generation,
Main header midway, user end)

Audit Approach

Step 2 : Monitoring
On line Trend (Pressure & Power)
Daily consumption
DCS display
Carry out FAD at frequent intervals
Calculate SEC and compare
Leakages test

Audit Approach
Step 3 : Macro level approach

Energy Share (%) or SEC (kW / MT of

product)
Cement plants : 1.5 2.0 kW/MT Clinker
Thermal Power : 0.4 0.6% (APC)
Benchmarking with similar units / sector

Demand (As per design) Vs actual

List Of Energy Saving Ideas In

Compressed Air System
Select correct size air compressor
Operate compressor at required
pressure
Install VFD
Minimise system losses - Proper line
sizing
Replace compressed air with blower
air
for agitation
Replace pneumatic tools with
electric tools

List Of Energy Saving Ideas In

Compressed Air System
Provide ball valves at the user point to
avoid compressed air wastage
Use transvector nozzles in air hoses
Cool inlet air to the compressor
Provide sensors to sense unloading
and switch off
Replace inefficient compressors

Confederation Of Indian Industry

Energy Management Cell