Aire Comprimido - Conceptos

Compressed Air Technology Concept
Compressed Air Background
Important industrial energy source Inherently inefficient Consumes up to 20% of industrial electrical
usage
$$$
Great energy & cost savings potential!
US DOE Industries of the Future Workshop Series
Lifetime Operation vs. First Cost
Typical Lifetime Compressed Air Costs Over 10 years
Maintenance 12% Equipment 12%
Assumptions include a 75-hp compressor operated two shifts, 5 days a week at an aggregate electric rate o $0.05/kWh over 10 years of equipment life.
Electricity 76%
Source: US Dept of Energy, Office of Industrial Technologies: Compressed Air Tip sheet #1. http://www.oit.doe.gov/bestpractices/pdfs/compressed_air1.pdf
Compressed Air Energy
Inefficient power source even if well maintained
Eight compressor horsepower
yields . . . One horsepower of compressed air
Compressed Air Energy
Ratio: 8:1
Leaks 5% C om pressed Pressure drop air energy 2% 15%
H eat of Heat of com pression compression 85% 84%
End users 9%
Compressed Air System
Supply
Distribution
Compressor System Controls Air Dryer Aftercoolers Air Filters Primary Storage Flow controls
Air piping Filters, lubricators,

regulators
End Uses
Pneumatic tools Mechanical drive Blowers Vacuum generators Etc . . .
Supply compressor types
Compressors
Positive Displacement
Dynamic
Reciprocating
Centrifugal
Axial
Single Acting
Double Acting
Rotary
Helical Screw
Liquid Ring
Scroll
Sliding Valve
Supply compressors
Reciprocating
Very efficient Requires frequent
maintenance Can be equipped for very efficient part loading Can be multistaged
Supply compressors
Rotary Screw
Easy to install Enables modulation
control Easy to maintain Can be single or double staged
Source: Gardner Denver
Supply control types

Average Power (% Full Load) 110% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0% 20% 40% 60% 80% 100% % Air Flow Capacity Variable Speed Load/Unload 3 gal/cfm storage Turn Valve Straight Modulation Modulation w/blowdown
(Outlet modulation) On/Off (not pictured) (Inlet)

(Inlet)
Variable Speed Drive Compressors
Allows precise matching of supply and demand Extremely efficient at low load Less efficient that standard compressors at full load Retrofitting standard compressors is problematic Not ideal for every application Best for precise constant pressure applications
Supply dryers
Refrigerated dryers
Utilized mechanical
cooling Air dew point limited by water freezing point (35 -40 F) Relatively inexpensive Generates condensate
Source: Smargon
Supply dryers
Regenerative desiccant
Water vapor is adsorbed
by desiccant fill Low air dew points (-40F to -100F Heated or unheated Requires 3-15% purge air No condensate generated
Source: Palatek
Efficient compressed air systems
Proper performance yields
Low operating costs Minimal downtime Clean, dry, dependable air Effective process control
Why make a change?
Great energy & cost savings potential!

Save energy (25% or more)
$$$
Reduce downtime Produce clean, dry air Eliminate maintenance crises
Technology - Common System Improvements
Benchmarking
Determine average power draw (kW) Determine total energy costs Determine marginal generation efficiency (kW/scfm)
Calculate energy savings potential for system improvements

Worksheet Estimate Your Compressed Air Cost
Common problem areas
Air Leaks No heat recovery High pressure drop Insufficient air storage Ineffective control strategy Multiple compressor operation not optimized
Base load vs. trim compressor

Inappropriate end uses Poor record keeping
Electric usage Air production
Air leaks
When was your last leak survey?

Leak surveys should be conducted quarterly!
Poorly maintained systems
Up to 40% leak rate Pressure problems We need to install another compressor.
Heat recovery
8 compressor horsepower yields 1 horsepower of compressed air . . .
Where does the other 7 horsepower go????
HEAT.
Heat recovery
80% of compressor input power may be recoverable Possible uses
Space heating Hot water heating Drying/curing room heating Heat source for desiccant dryer
100 hp @ full load 300,000 Btu/hr

Btu hr 1 MMBtu $5 300,000 4,000 6 hr year 1 10 Btu MMBtu
= $6,000
Heat recovery
Winter Operation
Compressor
Hot air to Plant
Heat recovery
Hot air Exhausted
Summer Operation
Compressor
Pressure drop compressor room
High P filters
Short radius elbows

Filter Filter
Compressor Storage Tank
Tee junctions
Compressor Air Dryer
Storage Tank Compressor To Plant
Unnecessary piping
High P dryer
Pressure drop (continued)
Distribution Worksheet Calculating the Cost of High Pressure

Drop
GOAL:
0 4 psig pressure drop in compressor room
Air storage
Rule of Thumb 4 gallons of storage per

compressor cfm
Remote storage for high periodic demands Wet vs. dry storage Piping rule
In at the bottom Out at the top!
Air Storage Compressor Loading
100 hp compressor with load/unload controls

120 100 Power (kW) 80 60 40 20 0 0
Loaded Blow down
Unloaded 10 20
30
40 Time (sec)
50
60
70
80Unloaded
Inadequate Storage (1 gal/cfm)

120 100
Power (kW)
80 60 40 20 0
0 25
Average Power = 82.9 kW
75 10 0 12 5 15 0 17 5 20 0 22 5 25 0 27 5 30 0 32 5
Compressor is fully loaded (delivering air) for 130 seconds

50
Time (sec)
Improved Storage (3 gal/cfm)

120 100
Power (kW)
80 60 40 20 0
25 50 75 10 0 12 5 15 0 17 5 20 0 22 5 25 0 27 5 30 0 32 5
Average Power = 63.0 kW
Compressor is fully loaded (delivering air) for 130 seconds

Time (sec)
Air Storage Generalized energy savings for increased storage in load/unload compressors
110%
Average Power (% Full Load)
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
Energy Savings
0%
20%
40%
60%
80%
100%
% Air Flow Capacity
Load/Unload 1 gal/cfm storage Load/Unload 5 gal/cfm storage
Load/Unload 3 gal/cfm storage Load/Unload 10 gal/cfm storage
Compressor controls
Control strategies impact compressor energy

consumption
Average Power (% Full Load) 110% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0% 20% 40% 60% 80% 100% % Air Flow Capacity Variable Speed Load/Unload 3 gal/cfm storage Turn Valve Straight Modulation Modulation w/blowdown
Compressor controls
Using the Most Efficient Control Strategy worksheet
Inappropriate End Uses
Anything that can be done
More effectively by another method More efficiently by another method
Inappropriate End Uses - Examples
Open blowing - Cooling, drying, clean-up Sparging - Aerating, agitating, oxygenating,
percolating Aspirating - Inducing flow in another gas (e.g., flue gases) Atomizing - Dispersing or delivering a liquid to a process as an aerosol Dilute phase transport - Transporting solids such as powders Dense phase transport - Transporting solids in batches
continued
Inappropriate End Uses - Examples
Vacuum generation - used with a venturi to generate

negative pressure mass flow Personnel cooling Open blowguns or lances Diaphragm pumps Cabinet cooling
Application of new technologies/concepts
Variable speed compressors Zero loss drains Air amplifying nozzles Solenoid shut off valves Demand Controller
Zero Loss Drains
Timer drains either:
Zero loss drains

remove liquid with no air loss
Waste air Fail to remove all liquid
Air Amplifiers
Amplifiers entrain still air to increase

air flow from blowing components Advantages
Increase blowing force Significantly reduced compressed air usage Reduced noise Fully adjustable Air curtains/knives Hand blow guns Blow off manifolds
Applications
Source: ARTX
Electric Solenoid Valves
Reduce leaks in piping to

equipment that is shut off Timer control Machine panel control Manual control
Demand Controllers
Isolate supply side from

demand side of system Appropriate only with adequate storage Help reduce air usage by minimizing pressure delivered to end users
Source: Zeks Compressed Air Solutions
Technology Next Steps
How do I optimize the performance of my compressed air system?
Systems approach (supply and demand)
Improving system performance
Assessing the entire system Identifying opportunities Quantifying benefits and costs Implementing most feasible projects
Implementation requires participation
Production Maintenance Management

IAC implementation trends and analysis

Description Times Recommended Implementation Rate Average Simple Payback (yrs) 0.3 0.3 0.7 1.2 1.2 1.5 0.9 0.7
Eliminate leaks in compressed air lines/valves Reduce the pressure of compressed air to the minimum required Eliminate or reduce compressed air used for cooling, agitating liquids, moving product, or drying Eliminate permanently the use of compressed air Remove or close off unneeded compressed air lines Cool compressor air intake with heat exchanger Substitute compressed air cooling with water or air cooling Do not use compressed air for personal cooling
4,529 2,193 568 127 53 22 20 18
74% 42% 44% 41% 42% 36% 35% 50%
How to start
Steps in evaluating your system Monitoring needs Best Practices Pitfalls
Treat compressed air like a fourth utility.
Steps to Evaluate Your System
Determine the cost of your air Check for air leaks Replace all dirty filters with high efficiency filters Set efficient control strategies
Base loaded compressors modulating control Trim compressors Load/unload control Check that all end use pressures are regulated Check for excessive generation pressure (<10 psi drop between compressor and highest end user)
Pressure issues
Address inappropriate end uses Check for adequate storage (>3 gal/cfm) Shut down idle compressors Check for moisture in storage tanks and drip legs
Monitoring
Air Pressure Problems Compressor Loading Power consumption Air Consumption Track using MS Excel or similar program
Pitfalls
Running at too high a pressure Considering compressed air as a free utility Higher pressure = more air Adding compressor horsepower to combat pressure
problems
Always have a compressed air audit completed before

adding additional compressors.
Inadequate storage/piping
ISO 14000
Formalized method for identifying and documenting

process improvements Can be used for benchmarking Proper use can lead to significantly reduced energy costs All program goals are set by company Benchmarking
Benchmarking revisited
Benchmarking should be part of a larger plan
Commit to Continuous Improvement
Implement Action Plan
Assess Performance
Set Goals
Create Action Plan
Evaluate Progress Re-Assess Goals
Assessing Resources
GO TO Compressed Air Resource List
In house assessment
Tools available from US DOE Air Challenge Program

US DOE Industrial Assessment Centers Energy Resources Center @ UIC Private energy service companies Equipment manufacturers
Assessment Resources
Energy Resources Center @ UIC www.erc.uic.edu - can provide
expertise in industrial compressed air systems, also will perform energy assessments for industrial clients. Industrial Assessment Centers http://www.oit.doe.gov/iac/ - will provide energy assessments (including compressed air systems) free of charge to qualified industrial clients. US DOE Compressed Air Challenge Program http://www.compressedairchallenge.org/ - provides a wide range of technical assistance materials, tools, and services to the industrial market. National Association of Energy Service Companies http://www.naesco.org/ - trade organization of companies that will perform energy audits and finance improvements. Rutgers IAC Self Assessment Guide http://iac.rutgers.edu/manuals/selfassessment.pdf - guide to assessing industrial plants for energy efficiency.
Hyperlinked Slides
Assessment Resources
Energy Resources Center @ UIC www.erc.uic.edu - can provide expertise in
industrial steam systems, also will perform energy assessments for industrial clients. Industrial Assessment Centers http://www.oit.doe.gov/iac/ - will provide energy assessments (including steam systems) free of charge to qualified industrial clients. US DOE Steam Challenge Program http://www.oit.doe.gov/bestpractices/steam/ - provides a wide range of technical assistance materials, tools, and services to the industrial market. National Association of Energy Service Companies http://www.naesco.org/ trade organization of companies that will perform energy audits and finance improvements. Steam System Survey Guide http://www.oit.doe.gov/bestpractices/steam/pdfs/steam_survey_guide.pdf guide to assessing industrial steam systems. Rutgers IAC Self Assessment Guide http://iac.rutgers.edu/manuals/selfassessment.pdf - guide to assessing industrial plants for energy efficiency.
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Compressed Air Technology Concept

Compressed Air Background

Great energy & cost savings potential!

US DOE Industries of the Future Workshop Series

Lifetime Operation vs. First Cost

Typical Lifetime Compressed Air Costs Over 10 years

Maintenance 12% Equipment 12%

US DOE Industries of the Future Workshop Series

Compressed Air Energy

Inefficient power source even if well maintained

Eight compressor horsepower

yields . . . One horsepower of compressed air

US DOE Industries of the Future Workshop Series

Compressed Air Energy

Leaks 5% C om pressed Pressure drop air energy 2% 15%

H eat of Heat of com pression compression 85% 84%

US DOE Industries of the Future Workshop Series

Compressed Air System

Air piping Filters, lubricators,

Pneumatic tools Mechanical drive Blowers Vacuum generators Etc . . .

US DOE Industries of the Future Workshop Series

Supply compressor types

US DOE Industries of the Future Workshop Series

Very efficient Requires frequent

US DOE Industries of the Future Workshop Series

Easy to install Enables modulation

control Easy to maintain Can be single or double staged

Source: Gardner Denver

US DOE Industries of the Future Workshop Series

Supply control types

(Outlet modulation) On/Off (not pictured) (Inlet)

Variable Speed Drive Compressors

US DOE Industries of the Future Workshop Series

US DOE Industries of the Future Workshop Series

Water vapor is adsorbed

US DOE Industries of the Future Workshop Series

Efficient compressed air systems

Proper performance yields

US DOE Industries of the Future Workshop Series

Why make a change?

Great energy & cost savings potential!

Reduce downtime Produce clean, dry air Eliminate maintenance crises

US DOE Industries of the Future Workshop Series

Technology - Common System Improvements

Calculate energy savings potential for system improvements

US DOE Industries of the Future Workshop Series

Common problem areas

Base load vs. trim compressor

Electric usage Air production

US DOE Industries of the Future Workshop Series

When was your last leak survey?

Poorly maintained systems

Up to 40% leak rate Pressure problems We need to install another compressor.

US DOE Industries of the Future Workshop Series

8 compressor horsepower yields 1 horsepower of compressed air . . .

Where does the other 7 horsepower go????

US DOE Industries of the Future Workshop Series

80% of compressor input power may be recoverable Possible uses

100 hp @ full load 300,000 Btu/hr

Hot air to Plant

US DOE Industries of the Future Workshop Series

Hot air Exhausted

US DOE Industries of the Future Workshop Series