Air Compressor Optimization

Like all electro-mechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak effici
minimize unscheduled downtime. Inadequate maintenance can increase energy consumption via lower compression efficiency,
leakage, or pressure variability. It also can lead to high operating temperatures, poor moisture control, excessive contamination
unsafe working environments. Most issues are minor and can be corrected with simple adjustments, cleaning, part replacement
elimination of adverse conditions.

This tool calculates the energy savings associated with making minor changes to your air compressor system. Each tab calcula
energy savings associated with one of the following changes:
Use outside air for air compressor intake
Reduce compressor air pressure
Repair compressed air leaks
Use synthetic lubricant in compressors
Recover waste heat from air compressor and use it to heat the plant in the winter
Use vortex nozzle for cleaning

Enter the data specific to your compressor in the section labeled Compressor Data. These inputs are shared by the six tabs bel
section. Each tab requires additional inputs specific to the changes listed above. The cumulative savings for implementing all th
is calculated at the bottom of the tool.

Air Compressor Optimization Calculator

General Inputs
Number of Compressors

Utilization Factor

Horse Power

N Value

Efficiency

91.5 %

Current Operating Pressure

Load Factor

0.84

Maximum Rated Pressure

Operating Hours

hrs

Atmosphere Pressure

Cost of Electricity

$/kWh

Demand Cost

Current Energy Consumption

kWh

Additional Resources
The US DOE Energy Management Portal: https://save-energy-now.org
The US DOE Compressed Air site: http://www1.eere.energy.gov/industry/bestpractices/compressed_air.html
The US DOE Compressed Air Tip Sheets:
http://www1.eere.energy.gov/industry/bestpractices/tip_sheets_compressed_air.html
The Compressed Air Challenge: http://www.compressedairchallenge.org/
Acknowledgement
This tool was created by the West Virginia University Industrial Assessment Center. For more information about
Industrial Assessment Center, visit their website www2.cemr.wvu.edu/~wwwiac/.

ization

maintenance to operate at peak efficiency and

ion via lower compression efficiency, air
ure control, excessive contamination, and
ustments, cleaning, part replacement, or

compressor system. Each tab calculates the

inputs are shared by the six tabs below this

ulative savings for implementing all the changes

1.25
psig
psig

14.7 psig
$/kWh-mo

practices/compressed_air.html

r.html

nter. For more information about the WVU

c/.

Reduce Air Pressure

Air Temperatures
Current Discharge Pressure
Proposed Discharge Pressure

psig
psig

Implementation Details
Labor Hours for Pressure Adjustment
Labor Rate

Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

$/hr

$
$
$

kWh
kW

Lbs

kWh

Outside Air
Air Temperatures
Current Average Intake Temperature
Average Outdoor Temperature

51 F

Implementation Details
Total Feet of Duct
Number of Elbows
Cost of Duct
Cost of 1 Elbow
Labor Hours
Labor Rate

Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

ft
$/ft
$
hrs
$/hr

$
$
$

kWh
kW

Lbs

kWh

Synthetic Lubricants
Implementation Details
Cost Difference per Gallon
Gallons Required

Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

$
gallons

$
$
$

kWh
kW

Lbs

kWh

Waste Heat
Waste Heat
Cost of Fuel
Number of Months Plant Required Space Heating

Savings
Annual Energy Savings
Annual Energy Savings
Total Annual Cost Savings
CO2 Savings

Current Energy Consumption

$/MMBtu

kWh
MMBtu

kWh

Lbs

Vortex Nozzle
Vortex Nozzle
Number of Vortex Nozzles
Compressed Air Usage Factor
SCFM from Nozzle
Operating Period of Nozzle
Usage Factor of Nozzle
Implementation Details
Cost per Nozzle
Labor Time per Nozzle
Labor Rate

Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

min/day

$
hrs
$/hr

$
$
$

kWh
kW

Lbs

kWh

Air Leaks
Air Temperatures
Line Pressure at the Leak
Average Line Temperature
Current Average Intake Temperature
Number of Air Leaks
Average Size (Diameter)
Implementation Details
Total Feet of Duct
Number of Leaks per year
Cost to Fix a Leak
Labor Hours to Fix a Leak
Labor Rate

Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

psig
F
F
in

ft
$
hrs
$/hr

$
$
$

kWh
kW

Lbs

0 kWh

Instructions for using the Air Compressor Tool

1

Enter the general inputs on the first tab. All fields must be filled in.

2
3

Enter input values into the 6 tabs (Outside Air, Reduce Air Pressure, Synthetic Lubricants, Waste
Heat, Vortex Nozzles, and Air Leaks). All of the tabs do not need to be filled in.
Results will appear in the grey section of each tab.

Key
Utilization Factors
Load Factors
Efficiency
Maximum Rated Pressure
Current Operating Pressure
Atmospheric Pressure

N Value

using the Air Compressor Tool

puts on the first tab. All fields must be filled in.

nto the 6 tabs (Outside Air, Reduce Air Pressure, Synthetic Lubricants, Waste
s, and Air Leaks). All of the tabs do not need to be filled in.
n the grey section of each tab.

Key
The maximum demand of a system divided by its rated capacity.
The average power divided by the peak power over a period of time.
Enter the efficiency of your system as a decimal value between 0 and
1.
The maximum pressure at which the manufacturer determines it is
safe to operate the nozzle.
The pressure the compressed air system is currently operating at.
If unknown, use the default value of 14.7 psig.

Compression factor based on type of compressor and polytropic

efficiency. Use the following list to determine the N-value for your
system.
N = 1.25 for screw compressors with polytropic efficiency of 80%
N = 1 for reciprocating compressor with single stage
N = 2 for reciprocating compressor with double stage