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Compressed Air - Fact Sheet

Compressed air systems are typically only 10-20% efficient, wasting the rest as heat. Regularly maintaining your compressor system and ensuring proper sizing, pressure matching, and intake air temperature can significantly reduce energy costs. Simple checks like monitoring for leaks and only using high pressure air when necessary can save thousands per year in electricity costs. Proper compressor system management is essential to cutting costs and greenhouse gas production.

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Minh Tran
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63 views

Compressed Air - Fact Sheet

Compressed air systems are typically only 10-20% efficient, wasting the rest as heat. Regularly maintaining your compressor system and ensuring proper sizing, pressure matching, and intake air temperature can significantly reduce energy costs. Simple checks like monitoring for leaks and only using high pressure air when necessary can save thousands per year in electricity costs. Proper compressor system management is essential to cutting costs and greenhouse gas production.

Uploaded by

Minh Tran
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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growing regions  |  strengthening industries

Compressed air
7
ISBN 0-9775169-1-1

Compressed air – It’s not just


hot air, it’s your money!

Eco-efficiency for the Marine Industry Fact Sheet


Do you want to
reduce how much you spend on compressed air?
improve the reliability of your air supply?
reduce and simplify the maintenance of your air supply?
reduce production of greenhouse gases?
It is essential to operate your system as efficiently as possible!
Compressed air systems are typically only 10% to 20% efficient, with the rest of the electricity
input lost as waste heat. [1]

Check to see if you are managing your compressed


air efficiently
Do you regularly service and maintain Do you ensure that high pressure air is not used for
the compressor system? purposes such as cleaning, cooling or drying, when low
Is your system correctly designed and sized? Consider pressure air from blowers or fans would be sufficient?
replacing large compressors operating at part load If the compressor operates under a range of loads,
with smaller systems that can operate at full load. For have you considered installing a variable speed drive?
large multi-compressor systems, consider an electronic Do you ensure that the air pressure is properly matched
control system that can match supply with demand. to the system demand? If more pressure is needed,
Do you regularly check for leaks by shutting off investigate reducing pressure drops by removing
all other equipment and listening, or by using complex, unused or long lengths of piping, and
an ultrasonic leak detector (see table 1)? ensuring that pipes are correctly sized (see table 2).
Do you ensure that the temperature of the intake
air is as low as possible, e.g. ducted air from
a cool, shaded area outside (see table 3)?
Table 1: Cost of compressed air leaks[2]
Equivalent hole diameter (mm) Quantity of air lost per single leaks Cost of leak
(sum of all leaks) (m³/year) ($/year)
Less than 1 mm 6,362 $144

From 1 mm to 3 mm 32,208 $731

From 3 mm to 5 mm 117,633 $2,669

Greater than 5 mm 311,738 $7,073

Assumption: 700 kPa system operating for 2,000h/year, electricity costs 15.125c/KWh

Queensland the Smart State


[2]
Every 50Kpa increase in pressure increases energy consumption by 4%

Table 2: Potential costs and energy savings that can be made by reducing air pressure [2]

Air pressure reduction

50kPa 100kPa
Average load Energy savings Cost savings Energy savings Cost savings
(kW) (kWh/yr) ($/yr) (kWh/yr) ($/yr)
7.5 1,195 $182 2,390 $361

11 1,755 $265 3,510 $531

15 2,390 $361 4,780 $722

22 2,945 $446 5,890 $891

30 4,380 $662 8,760 $1,325

37 5,975 $904 11,950 $1,807

55 8,760 $1,325 17,520 $2,651

75 12,750 $1,928 25,500 $3,857

110 18,350 $2,775 36,700 $5,597

Assumptions: 700 kPa system operating for 2,000 hrs per year, electricity costs 15.125 cents/kWh

[2]
Every 3°C reduction in inlet temperature reduces energy consumption by 1%

Table 3: Potential costs and energy savings that can be made by reducing the temperature of compressor inlet air [2]

Reduction to intake air temperature

6°C reduction 10°C reduction


Average load Energy savings Cost savings Energy savings Cost savings
(kW) (kWh/yr) ($/yr) (kWh/yr) ($/yr)
7.5 300 $45 495 $76

11 440 $66 725 $110

15 600 $91 990 $150

22 880 $132 1,450 $219

30 1,200 $182 1,980 $299

37 1,480 $223 2,440 $369

55 2,200 $333 3,625 $548

75 3,000 $454 4,950 $749

110 4,400 $666 7,260 $1,099

Assumptions: 700 kPa system operating for 2,000 hrs per year, electricity costs 15.125 cents/kWh

Ecobiz can assist you to reduce costs and improve eco-efficency in your business Call 1300 369 388 for further information.

Queensland the Smart State


Useful websites
Compressed air calculator:
SEDA Energy Smart - www.energysmart.com.au/wes/DisplayPage.asp?PageID=53

Buying new equipment calculator:


Australian Building Greenhouse Rating - www.abgr.com.au/tenants/tenantsCalcTEMH1.asp

How much is your business spending on compressed air each year?


1. How much power do you consume running your compressor (assume 100% load)?
hours of daily operation x power rating x days of use each year = power consumption

(hrs) x (kW) x (days) = (kWh/yr)

2. How much is it costing you annually to run your compressor?


cost for electricity x power consumption = Annual cost to run compressor

($/kWh) x (kWh/yr) = ($/yr)

3. Options for improvement?

References
1. EM (2005) Technical Information Sheet - Compressed Air Systems, Efficiency Maine, Augusta, Maine, USA. Retrieved 12-12-2005 from: www.
efficiencymaine.com/business/pdfs/Compressed_Air_TDS.pdf
2. SEDA (2000) Energy Smart Compressed Air Calculator, Sustainable Energy Development Authority, Sydney. Retrieved 12-12-2005 from: www.energysmart.
com.au/wes/displayPage.asp?PageID=53

For further information


Ecobiz can assist you to reduce costs and improve eco-efficency in
your business Call 1300 369 388 for further information.
Eco-efficiency Project Officer
SD3432  08/06

Marine Industries and Fibre Composites Group


Department of Tourism, Regional Development and Industry
Telephone: 07 3227 5756
[email protected]
www.marine.industry.qld.gov.au

Queensland the Smart State

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