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Industrial Assessment Center | 263 Link Hall, Syracuse, NY 13244 | Phone > 315.443.1523 | Fax > 315.443.909 | [email protected] | http://IAC.syr.edu
Inappropriate Air
Use
• Compressed Air is Expensive!
• Should NOT be used for
• Cleaning
• Cooling (personal A/C)
• Drying
• Open Blowing
• Using a mechanical device is a little trickier
but much more cost effective!
CONTACT US
SyracuseIAC
BHP reduction per Discharge Pressure drop
0
5
10
15
20
25
30
130 120 110 100 90 80 70 60 50
Discharge Pressure (PSIG)
Ap
pro
xim
ate
Dec
rea
se in
BH
P (
%)
Line Pressure
• Many facilities run their air compressors
at a higher pressure than is actually
needed.
• Dropping the line pressure to the
minimum required by the facility results in
significant energy savings.
• Regular maintenance including changing
filters and repairing leaks helps to
decrease the pressure drop between the
compressor supply and demand.
Intake Air
• Outside air (especially in Upstate NY) is on
average, cooler and denser than indoor air
and therefore requires less energy to
compress.
o Average Facility Temperature: 70°F
(Although mechanical rooms are usually
hotter!)
o Average Outdoor Temperature: 45°F
Leaks The number one source of wasted energy!
• Up to 20% of compressed air wasted
• Cause pressure drop throughout system
• Affect production
• Shorten system life
Energy Savings in Compressed Air Systems
$627
$2,614
$10,350
Look how much a facility running a
compressor at 110 psi 24/7 and an
electricity cost of 8 ¢/kWh, is losing!
Duct Outside Air to Compressor Intake
Number of
Recommendations
Percent
Implemented
Average
Savings
Average
Simple
Payback
148 57% $3,287 5 months
Reduce Compressed Air System Line Pressure
Number of
Recommendations
Percent
Implemented
Average
Savings
Average
Simple
Payback
163 61% $5,886 Immediate
Repair Leaks in Compressed Air System
Number of
Recommendations
Percent
Implemented
Average
Savings
Average
Simple
Payback
156 88% $4,517 2 months
Discontinue Inappropriate Compressed Air Use
Number of
Recommendations
Percent
Implemented
Average
Savings
Average
Simple
Payback
11 45% $14,426 5 months
Compressors
Dryer Receiver Tank
Distribution Lines
Temperature gun used to
measure the intake
temperature.
IAC student engineers
consult a display panel
IAC student engineers
consult a compressor
display panel
Approximately 2.5% power
decrease for every 5 psi
reduction!
100 HP Ingersoll-Rand
Compressor ducting in
outside air
A Program Sponsored by the
U.S. Department of Energy
Above graphic taken from Improving Compressed Air
System Performance: a sourcebook for industry
by the U.S. DoE EERE Office
