Program Name or Ancillary Text eere.energy.gov

Three-Day Compressed Air Energy Saving Assessment

Kelly KissockDirector: University of DaytonIndustrial Assessment CenterDayton, Ohio U.S.A.

U.S.-Brazil Industrial Energy Efficiency WorkshopRio de Janeiro, Brazil August 8-11, 2011

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Overview of 3-Day Assessment

• Before Visit– Send data loggers to plant– Ask plant to install Air Master+ software

• Day 1– Brief plant management– Inspect compressed air plant and major end-uses of compressed air– Down-load and analyze pressure and current data

• Day 2– Show “Energy Efficient Compressed Air” slide show to production and

maintenance personnel.– Gather additional data to quantify savings– Enter data into Air Master+ to quantify savings

• Day 3– Teach staff how to use Air Master+– Closing meeting with management to discuss results.

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Plant Inspection

Plant Inspection

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Compressed Air Plant

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Compressor Types and Sizes

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Compressor Controls

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Pressure in Compressed Air Plant

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Compress Indoor or Outdoor Air

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Compressed Air Dryer

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Compressed Air Storage

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Condensate Drains

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Compressed Air Piping

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Pressure at End Uses

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End Uses

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Power and Pressure Data

Power and Pressure Data

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Load/unload and Modulation Control

180-hp Rotary Screw Air Compressor - Load/Unload Control

0

50

100

150

200

250

14:40:00 14:42:00 14:44:00 14:46:00 14:48:00 14:50:00 14:52:00 14:54:00 14:56:00 14:58:00 15:00:00

Cur

rent

Dra

w (A

mps

)

150-hp Rotary-Screw Air Compressor - Inlet Modulation Control

0 20 40 60 80

100 120 140 160 180 200

13:40:00 13:45:00 13:50:00 13:55:00 14:00:00 14:05:00 14:10:00 14:15:00 14:20:00

Current Draw (Amps)

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Two Compressors Properly Staged

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Size Dryer for DP< 5 psi

Low Flow: DP = 1 psi High Flow: DP = 6 psi

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Nights and Weekend Operation

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Compressed Air Storage

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Production and Maintenance Briefing

Production and Maintenance Briefing

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Install Nozzles on Air Tubes

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Install Solenoid Valves on Part Movers

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Use Blowers Instead of Compressed Air

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Use Electric Pumps Instead of Air Pumps

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Activate Bag House Air Pulses with Pressure Drop

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Identify and Fix Leaks

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Add Storage to Decrease Cycling

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Use Sequencer to Stage Multiple Compressors

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D.O.E. Air Master+ Software

• AIRMaster+ provides a systematic approach for assessing the supply-side performance of compressed air systems.

• AIRMaster+ evaluates the energy savings potential of any or all of the following eight energy efficiency actions:

• Reduce air leaks• Improve end-use efficiency• Reduce system air pressure• Use unloading controls• Adjust cascading set points• Use automatic sequencer• Reduce run time• Add primary receiver volume

• http://www1.eere.energy.gov/industry/bestpractices/

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Short Concise Report

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Thank you!