Energy saving opportunities in

compressed air system

• Pressure reduction

• Air leakage losses

• Intake losses

• Intake air temperature

• Pipe resistance losses

 Energy saving opportunities in
compressed air system
• Waste heat recovery

• Control system

• Dry air

• Misuse of air

• maintenance
 The current
The current for
for the
the 33 phases
phases
measurements
measurements

Loaded(amps) Unloaded(amps)

Phase 1 243 178

Phase 2 245 176

Phase 3 247 178

Average 245 177.4

The time for load-unload cycles
during production

Loaded(sec) Unloaded(sec) Total cycle(sec)

50 10 60

51 8 59

51 9 60

50 11 61
The time for load-unload cycles
outside production hours

Loaded(sec) Unloaded(sec) Total cycle(sec)

25 20 45

26 22 48

25 21 46

27 20 47
 Solution
• Estimate compressor load (kW) :

 Loaded cycle = 1.732 x 245 x 0.85 x

41v / 1000 = 149.6 kW

 Unloaded cycle = 1.732 x 177.4 x 0.6 x

415v / 1000 = 76.5kW
 Calculate compressor average
load (kW) during product period

• Average load cycle time = ( 50 + 51 + 51 +

50 ) / 4 = 50.5 sec

• Average total cycle time = ( 69 + 59 + 60 +

61 ) / 4 = 60 sec

• Loaded (%) = 50.5 / 60 = 84 %

 Average power

• = power loaded(% load) + power unloaded(%

unloaded)

• = ( 149.6 x 0.84 ) + ( 76.5 x (1 – 0.84)) = 137.9 kW

 Annual energy (kWh/year)
• = Average power (kW) x annual operation
hours

• = 137.9 kW x 6,000 hours/ year

• = 827,400 kWh / year

 Estimate the compressor power during
the leak test
• Average loaded cycle time
= ( 25 + 26 + 25 + 27 ) / 4 = 25.7 sec

• Average total cycle time

= ( 45 + 48 + 46 + 47 ) / 4 = 46.5 sec

• Estimate percent loaded = 25.7 / 46.5 = 55%

 Estimate the compressor power during
the leak test

• Average power
= ( power loaded x % loaded time ) + (
power unload x % unloaded time)
= (149.6 x 0.55) + (76.5 x (1 – 0.55
= 116.7 kW
 Estimate energy and cost due to
leaks
• Power due to air leaks
= power during leak test - Measured
power at unloaded condition
= 116.7kW – 76.5kW = 40.2 kW
• Estimate cost of leaks
= power due to leaks x annual operating
hours x cost of energy
= 40.2 kW x 6000 hours/year x 25 sen/kWh
= RM60,3000/year
 Estimate cost saving from a leak
reduction program

• Assume that 80% of leaks can eliminated

= 0.8 x cost of leaks
= RM 48,240/ year