AirCompressors

TwoTypes
PositiveDisplacement
Reciprocating RotaryScrew

Dynamic
Centrifugal Axialflow

RotaryScrewCompressors

RotaryScrewCompressors
Direct DirectInjection Injection,Oil Oilinjected injected,Direct Direct cooled,Flooded
Variousnamesaresuggestiveofthedirectcontact oflubricating/coolingoilontotherotatingscrew p parts Requiresaseparatorjustaftercompressionto removeoilfromthecompressedair

Oilfree,Oilless,Drycompressorsalso available(foodindustry,hospitals,etc.)

Animations
http://www http://www.compair.ca/info.php?section=com compair ca/info php?section=com pressor

http://www.icsltd.ca/Rotary%20screw%20working%20principle.htm

Duetooverlappingandcontinuouscompressioncycles,therotaryscrew designgeneratesvirtuallynovibration.Disturbingnoiseisminimized, providingawiderchoicefortheunit'slocationonthevehicle.

Theendsofthe rotorsuncover theinlet:air entersthe compression chamber chamber.

Theairis Astherotorsturn, Compressedair entrappedinthe thecompartment leavesthroughthe 'compartment' becomes outletport formedbyamale progressivelysmaller, lobeandafemale therebycompressing flute flute. theentrappedair. air

CentrifugalCompressors

CentrifugalCompressors
http://www http://www.youtube.com/watch?v=L65Fwh9c youtube com/watch?v=L65Fwh9c w50&feature=PlayList&p=43D84745F420D43F &index=14

http://www1.eere.energy.gov/industry/bestpractices/pdfs/compressed_air_sourcebook.pdf

CompressorControls
On/Off(Start/Stop) Modulated Load/Unload d/ l d VariableDisplacement VariableSpeedDrive(VSD)

100 Amps Interval data (4 seconds) for System (Not Assigned) and Periods (Not Assigned) 12/ 15/ 2008 11:54:06 PM to 12/ 17/ 2008 12:32:05 AM

200

300

400

500

600

Tu e 0 Tu 1:0 0 e 0 Tu 2:0 0 e 0 Tu 3:0 0 e 0 Tu 4:0 0 e 05 : Tu 00 e 06 Tu :0 0 e 07 Tu :0 0 e 0 Tu 8:0 0 e 0 Tu 9:0 0 e 1 Tu 0:0 0 e 1 Tu 1:0 0 e 12 : Tu 00 e 13 Tu :0 0 e 14 Tu :0 0 e 1 Tu 5:0 0 e 16 Tu :0 0 e 1 Tu 7:0 0 e 1 Tu 8:0 0 e 1 Tu 9:0 0 e 2 Tu 0:0 0 e 21 Tu :0 0 e 2 Tu 2:0 0 e W 23:0 ed 0 00 :0 0

Curr_250_hp_rent (Amps) Curr_250_hp (Amps) Curr_100_hp (Amps)

100

200

300

400

Amps

0 Interval data (4 seconds) for System (Not Assigned) and Periods (Not Assigned) 12/ 16/ 2008 10:24:15 AM to 12/ 16/ 2008 10:33:08 AM Curr_250_hp_rent (Amps) Curr_250_hp (Amps) Curr_100_hp (Amps)

10 :2 4 10 :20 :2 4 10 :40 :2 5 10 :00 :2 5 10 :20 :2 5 10 :40 :2 6 10 :00 :2 6 10 :20 :2 6 10 :40 :2 7 10 :00 :2 7 10 :20 :2 7 10 :40 :2 8 10 :00 :2 8 10 :20 :2 8 10 :40 :2 9 10 :00 :2 9 10 :20 :2 9 10 :40 :3 0 10 :00 :3 0 10 :20 :3 0 10 :40 :3 1 10 :00 :3 1 10 :20 :3 1 10 :40 :3 2 10 :00 :3 2 10 :20 :3 2 10 :40 :3 3: 00

TypicalCompressor Controls/Characteristics
100 90 80 70 60 50 40 30 20 10 0 0

Pow wer,perce entoffu ullload

Start/Stop) Mod

(Load/Unload) Mod/Unload

50 Capacity(Flow),percent

100

Compressors SavingEnergy
Reduceruntime turnoffwhennotneeded Lowersystempressuretolowestpossiblelevel Repair i leaks l k Recoverwasteheat Additionalsystemvolume(load/unloadonly) Reduceuseofpneumatictools

LowerPressure
Ruleofthumb: Forsystemsinthe100psigrange, every2psidecreaseindischargepressure resultsinapproximately1percentpower decreaseatfulloutputflow

LowerPressure UnregulatedUsage
Ruleofthumb: Forsystemswith30to50percentunregulated usage,a2psidecreaseinheaderpressurewill decreaseenergyconsumptionbyabout0.6to 1.0percentbecauseofunregulatedair Totalis1.6%to2%powerdecreaseforevery 2psidrop

LowerPressure
Calculations
Estimateannualenergyusage (assumecompressorrunsfullyloadedunlessyou knowotherwise) KWh=HPx0.746xLFxH Computereductions:every2psireductionisa 1.6%to2.0%reductioninpower,soeach2psi reductiongives0.984to0.98ofthepreviousvalue

Example ReducePressure
A150hpcompressorruns90%loaded12 hoursperday5daysperweekatadelivery pressureof110psi.Estimatetheenergyand costsavingsifthepressureisreducedto 90psi.Assume$0.05/kWhforelectricity. Solution: Assumea1.8%reductionforevery2psito accountfor f unregulated l dusage. Firstestimatetheannualenergyusage:

Example/Solution ReducePressure
kWh=HPx0.746xLFxH kWh =150hpx0.746kW/hpx0.9x3120hrs 110 314 215 314,215 =314 314,215 215kWh/yr 108 308,559 =0.982*B1 Computereductions 106 303,005 104 297,551 (Tableatright) 102 292,195 EnergySavingsare52,191kWh/yr 100 286,936 98 281,771 Netreductionis16.6% 16 6% 96 276,699 94 271,718 At$0.05/kWh,thisamounts 92 266,827 to$2,610/yr 90 262,025 262 025

ReduceAirLeaks
Atypical yp p plantthathas notbeenwellmaintained willlikelyhavealeakrate equalto20percentof totalcompressedair productioncapacity. Proactiveleakdetection andrepaircanreduce leakstolessthan10 percentofcompressor output

ReduceAirLeaks
Calculations
Savingsrealizeddependonthetypeof compressorcontrols Inputpowerdecreaseslinearlywithdecreasein airflow
Control Slope(kW%/cfm%) Start/Stop 100/100 Mod 35/100 Unload 80/100

Sofora10%reductioninflowbyrepairingleaks
Control kW% Start/Stop 10% Mod 3.5% Unload 8%

Example ReduceLeaks
Thecompressorfromthepreviousexample usesmodulatingcontrols.Thesystemreduces flowby10%throughaleaksprogram. Estimateenergyandmonetarysavingsat $0.05perkWh. Solution: Fora10%reductioninflow,a3.5%reduction i powerresults: in l

Example ReduceLeaks
Savings=262,025 262 025kWh/yrx0.035 0 035 =9,171kWh/yr At$0.05/kWh, $0 0 /k h this hi comesto CostSavings=9,171kWh/yrx$0.05/kWh =$459

RecoverWasteHeat
Asmuchas80to93percentoftheelectrical energyusedbyanindustrialaircompressoris convertedintoheat. heat Inmanycases,aproperlydesignedheat recoveryunitcanrecoveranywherefrom50 to90percentofthisavailablethermalenergy andputittousefulworkheatingairorwater. water Netpotentialis40%to84%recovery

Example RecoverWasteHeat
Thecompressorfromthepreviousexampleis aircooled.Estimatetheamountofnatural gasheatingthatcouldbedisplacedduring twelveweeksofwinteroperation,andthe costsavingsat85%combustionefficiencyand $4 00/MMBtu $4.00 /MMB fuel f lcost. Solution: A Assume 50%of fthe h i inputpowercanbe b recovered:

Example RecoverWasteHeat
Savings=HPx2545Btu/hphrx50%xH =150hpx2545Btu/hphrx0.50 x(12wksx5days/wkx12hrs/day)x 1MMBtu /1E6Btu =137.4 137 4MMBtu MMBt CostSavings=Savings/EFFxFuelCost =137.4/0.85x$4.00 $ =$647

Examples Summary
Measure Baselineoperation ReducePressure RepairLeaks RecoverWasteHeat* TOTAL SAVINGS Energy TOTAL SAVINGS Cost Energy 314,215kWh/yr 52,191kWh/yr 9,171kWh/yr 40,270kWh/yr (137.4MMBtu/yr) 101,632kWh/yr $3,715 Cost/Savings $15,711/yr $2,610 /yr $458/yr $647/yr 16.6% 2.9% 4.1% 32.3% 23.6%

*Assumesplantcanuseallavailableheatovera12weekperiod

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