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THE REAL COST OF COMPRESSED AIR
2015 WEA Conference
Presented by Jeff Treble
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COMMITTED TO SUSTAINABLE PRODUCTIVITY
We stand by our responsibilities towards our customers, towards the environment and the people around us.We make performance stand the test of time. This is what we call – Sustainable Productivity.
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Compressor Air Technologies
Air Compressor Lifecycle Costs
Variable Speed Drive
Onsite Nitrogen Generation
THE REAL COST OF COMPRESSED AIR
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COMPRESSOR TECHNOLOGIES
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COMPRESSED AIR TECHNOLOGIES
Oil-injectedscrew compressors
Oil-free piston compressors
Oil-injected pistoncompressors
Oil-free water-injected screw compressors Oil-free tooth
compressors
Purchased products
Filters
Compressor controls
Oil-free scroll compressors
Desiccant dryers
Refrigerant dryersMembrane dryers
Oil/water separators
Drains
Active carbon filter
Membrane nitrogen
generators
PSA nitrogen generators
PSA oxygen generator
Oil-sealed rotary screw vacuum
pumps Oil-sealed rotary vane vacuum
pumps
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COMPRESSOR TECHNOLOGIES
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AIR COMPRESSOR LIFECYCLE COSTS
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment, Maintenance & Energy
Inbuilt Water Separator Automatic
Water Drains
70%
15%
15%
Energy
Maintenance
Investment
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Condensate Treatment
Integrated Dryer
Inbuilt Water Separator Automatic
Water Drains
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Condensate Treatment
Integrated Dryer
Inbuilt Water Separator Automatic
Water Drains
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Oil Carryover
Oil Separator Vessel
Lubricants
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Oil Carryover
Oil Separator Vessel
Lubricants
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Sound Attenuation
Oil Separator
70dB(A)
3db(A) Sounds Twice as Loud!
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Sound Attenuation
Oil Separator
70dB(A)
3db(A) Sounds Twice as Loud!
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Drive Type
Belt Drive Direct Drive
Motor Element
Gearbox Drive
Efficiency
Capital Cost
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AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Compressor Performance vs. Efficiency
Free Air Delivery
Specific Energy
Requirement
365385405425445465485505525
1000 2000 3000 4000 5000 6000 7000 8000
SER
(J/l)
SPEED (RPM)
SER Performance (7BAR)
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AIR COMPRESSOR LIFE CYCLE COSTSService
Maintenance Plans
Genuine Parts
PreventativeMaintenance
Plan
Ad-hocServing
TotalResponsibility
Plan
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AIR COMPRESSOR LIFE CYCLE COSTSService
Maintenance Plans
Genuine Parts
Every 1 Bar in pressure drop equates to 7%increase in energy consumption. Consider a75kW compressor that uses 80kW consistentlyover 8,000 hours, with electricity cost of 25cents per kilowatt hour. 1 Bar pressure drop =$11,200 per year
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AIR COMPRESSOR LIFE CYCLE COSTSEnergy
The yearly electrical cost of operatinga 75kW compressor that uses 80kWconsistently over 8,000 hours, withelectricity cost of 25 cents per kilowatthour is $160,000!
Air Demand Profile n°1
0
20
40
60
80
100
120
0:15
1:15
2:15
3:15
4:15
5:15
6:15
7:15
8:15
9:15
10:1
5
11:1
5
12:1
5
13:1
5
14:1
5
15:1
5
16:1
5
17:1
5
18:1
5
19:1
5
20:1
5
21:1
5
22:1
5
23:1
5
Time
Cap
acity
in l/
s
SundayMondayTuesdayWednesdayThursdayFridaySaturday
Air Demand Profile n°2
0
20
40
60
80
100
120
0:15
1:00
1:45
2:30
3:15
4:00
4:45
5:30
6:15
7:00
7:45
8:30
9:15
0:00
0:45
1:30
2:15
3:00
3:45
4:30
5:15
6:00
6:45
7:30
8:15
9:00
9:45
0:30
1:15
2:00
2:45
3:30
Cap
acity
in l/
s
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Air Demand Profile n°3
0
20
40
60
80
100
120
0:15
1:15
2:15
3:15
4:15
5:15
6:15
7:15
8:15
9:15
10:1
5
11:1
5
12:1
5
13:1
5
14:1
5
15:1
5
16:1
5
17:1
5
18:1
5
19:1
5
20:1
5
21:1
5
22:1
5
23:1
5
Time
Cap
acity
in l/
s
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
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AIR COMPRESSOR LIFE CYCLE COSTSData Logging and Simulation
Take measurements of the system
Download data from M-Box Do SimulationsLoad profile
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AIR COMPRESSOR LIFE CYCLE COSTS
Correct Sizing of compressor
Accurate simulation of alternate technology
Guaranteed energy savings
Data Logging and Simulation
Measured Against Actual Use
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VARIABLE SPEED DRIVE
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VARIABLE SPEED DRIVETraditional Compressors Generate Losses
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VARIABLE SPEED DRIVE
Compressor Speed regulates to keep up with Demand– Eliminates Blow Off and Unloaded Losses
Keeping up with demand
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VARIABLE SPEED DRIVE
Average saving 35% of energy– 35% x $160,000 = $56,000
Must Check!– Turn Down Ratio at least 80%– Oil Separator does not blow off– Hi Torque Motor– VSD Motor Bearings– Integrated Design– Adjustable Pressure
Traditional VSD
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VARIABLE SPEED DRIVE
Average saving 50% of energy– 50% x $160,000 = $80,000
Same Benefits as traditional VSD except:– Uses highly efficient Oil Cooled Permanent
Magnet Motor, IP66– Optimised element Design– Direct Drive– Optimised Inlet valve– Smaller Cooling Fan– Smaller footprint– Lower noise levels
Next Generation VSD
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ONSITE NITROGEN GENERATION
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ON SITE NITROGEN GENERATION
Benefits of onsite generation– Cost– Self Reliance– Occupational Health and Safety– Continuous Supply
It’s time to wean yourself off the bottle
Nitrogen
Oxygen
Argon
Hydrogen
Neon
Helium
Kripton
Xenon
Carbon Dioxide
Gas Type Volume %
78,08
20,94
0,93
0,0005
0,0019
0,0005
0,0001
0,000008
0,02-0,04
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ON SITE NITROGEN GENERATION
Membrane– Compressed Air Passes through membrane chamber– Because of molecule size
Oxygen permeates through membrane wallNitrogen rich air Flows through membrane
Pressure Swing Absorption– Compressed Air passes through CMS Chamber– Because of molecule size
Oxygen molecules attach to CMSNitrogen rich air Flows through CMS
Technology
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ON SITE NITROGEN GENERATIONGenerate Nitrogen on Site and $ave
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COMMITTED TOSUSTAINABLE PRODUCTIVITY.
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