Why Variable Speed Drive

CECCATO IVR

Energy savingsfacts and figures

The cost of compressed airits not free
70% of industrial electrical consumption is for electric motors
compressed air consumes 10 to 20 % of industrial electrical capacity
compressed air consumes over 80 TWh per year in the EU
this accounts for over 55 million tons of CO2 emissions per year
electricity comprises more the 70% of the total life cycle cost of a
compressor

Energy savingsfacts and figures

Move the buying decision from purchase
cost to Life Cycle Cost.
Consider as an example:

energy

75 kW oil injected screw

compressor
Investment cost: 25,000
Maintenance cost/yr: 2,500

> 70%

maintenance
10%

investment
20%

Energy cost/yr: 50,000

Energy savingsfacts and figures

With IVR energy savings of 35% or more can be realized
over traditional compressor regulation

IVR

With our previous example this means the

investment is paid in less than two years.

Energy savingsthe results

Air Demand Profile n1

Air Demand Profile n2

120

140
100

80

Capacity in l/s

Capacity in l/s

120

Sunday
Monday

60

Tuesday
Wednesday
40

Thursday
Friday

20

Sunday

100

Monday
80

Tuesday

60

Wednesday
Thursday

40

Friday

20

Saturday

Saturday
0:00

22:45

21:30

20:15

19:00

17:45

16:30

15:15

14:00

12:45

11:30

9:00

10:15

7:45

6:30

5:15

4:00

2:45

1:30

0:00

22:45

21:30

20:15

19:00

17:45

16:30

14:00

Time

15:15

12:45

11:30

9:00

10:15

7:45

6:30

5:15

4:00

2:45

1:30

0:15

0:15

0
0

Time

88%
12%

Air Demand Profile n?

140

120

100

Sunday
Monday

80

Tuesday
Wednesday
Thursday

60

40

Friday
Saturday

20

0:00

22:45

21:30

20:15

19:00

17:45

16:30

15:15

Time

14:00

12:45

11:30

10:15

9:00

7:45

6:30

5:15

4:00

2:45

1:30

0
0:15

Capacity in l/s

Average load
determines the
compressors
power
consumption

Peak load
determines the
compressor
selection

Energy savingshow are they archive

Pressure settings: load/no load
regulation
bar
8
7.5

p unload

6.5

p load

6.0

minimum air net pressure

6
0

1 b a r r e p r e s e n t s 6 % e n e r g y
consumption

Slide 15 of 34

Energy savingsreal life test

IVR Test results Real life
Air Demand Profile n3

Air Demand Profile n2

Thursday
40

Friday

20

Saturday

60
40

Friday
Saturday

20

22:45

21:15

19:45

18:15

16:45

15:15

13:45

12:15

9:15

10:45

7:45

0:00

22:45

21:30

20:15

19:00

17:45

16:30

15:15

14:00

12:45

11:30

9:00

10:15

7:45

6:30

5:15

4:00

2:45

1:30

0:15

0:00

21:30

20:15

22:45

16:30

19:00

15:15

17:45

14:00

12:45

9:00

11:30

10:15

5:15

7:45

4:00

2:45

6:30

Time

Tuesday
Wednesday
Thursday

80

0
1:30

Wednesday

6:15

20

Tuesday

60

4:45

40

80

Sunday
Monday

100

3:15

60

Monday

1:45

Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday

120

Sunday

100

0:15

80

140

Capacity in l/s

120

Capacity in l/s

140

100

0:15

Capacity in l/s

Air Demand Profile n1

120

Time

Time

YEARLY ENERGY

SAVINGS

Air Demand
Profile No.

MSC45IVR
kWh

RMD90IVR
kWh

Percentage

1
2
3

108.500
43.525
26.075

195.300
78.345
46.935

38%
29%
14%

Weighted
average:

83.713

150.683

35%

Soft starting
Soft start and stop operation

components

Starting Current Comparison

800

700

% Full Load Current

no starting current
peaks
soft starting and
stopping at a controlled
acceleration and
deceleration time
no penalties for starting
current peaks
unlimited restarting
meaning complete
elimination of unload
energy consumption
less stresses on
electrical and
mechanical

600

Star Delta
DOL
Soft Starter
IVR

500

400

300

200

100

0
0

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

seconds

Easy calculation

by hand

The old fashioned pencil, paper and slide

rulerough but fast and effective
Energy cost example
Given: demand 1098 cfm 10 hours/day
Two units 784 cfm selected
Load factor = 1098 / 784 = 1.4
Total compressor power consumption
Compressor 1 (full load) = 140 kW
Compressor 2 (40% load) = 35 kW+40%(140-35kW) = 70.7 kW
Compressor 1 + 2 = 211 kW
Weekly electricity use
5 days x 10 hrs/day x 211 kW = 10,550 kWh
Annual cost of electriciy
50 weeks x .07 euro/kWh x 10,550 kWh/week = 36,925

Energy saving

I.

Part load power comparison

by hand
Consider:

Capacity load/no load

IVR
%
% power
% power
100
90
80
70
60
50
40
30
20
10
0

100
92.5
85
77.5
70
62.5
55
47.5
40
32.5
25

100
90
80
70
61
53
43.5
35
26
0
0

1st
2nd
3rd

55 kW
fixed speed

IVR

FL input power, kW
Capacity, l/s

71
150

60
137

Cost of electricity: 0.10 /kWH

Plant demand profile
1st shift 118 l/s 2200 hrs/yr
2nd shift 83 l/s 2200 hrs/yr
3rd shift 47 l/s 2200 hrs/yr
Fixed speed power cost = 40,378

II.
Shift

Data

1st shift = 71 kW x .93 x .10 /hr x 2200 hours = 14,527

2nd shift = 71 kW x .865 x .10 /hr x 2200 hours = 13,511

Fixed speed Fixed speed

IVR
IVR
load factor
% power load factor % power
0.79
0.55
0.31

93
86.5
79

0.86
0.6
0.34

86
61
38

3rd shift = 71 kW x .79 x .10 /hr x 2200 hours = 12,340

IVR power cost = 24,420
1st shift = 60 kW x .86 x .10 /hr x 2200 hours = 11,352
2nd shift = 60 kW x .61 x .10 /hr x 2200 hours = 8,052
3rd shift = 60 kW x .38 x .10 /hr x 2200 hours = 5,016

Savings with IVR = 15,958

IVR

range

Type
CSB 30/8 IVR

CSB 30/10 IVR

CSB 50/8 IVR

CSC 50/10 IVR

Type
RL 75/8 IVR

RL 75/10 IVR

DRA 100 IVR

DRA 125 IVR

bar

psi

HP

kW

l/min

cfm

db(A)

gas

kg

116

30

22

3530

124

68

1 1/4"

1330

815

1190

470

1100

39

3170

112

68

1 1/4"

1330

815

1190

470

990

35

6080

215

70

1 1/4"

1100

1390

1805

850

1760

62

5540

196

70

1 1/4"

1100

1390

1805

850

1560

55

10

10

145

116

145

30

50

50

22

37

37

bar

psi

HP

kW

l/min

cfm

db(A)

gas

kg

116

75

55

9038

319

73

1 1/2"

1980

1160

2020

980

2449

87

8100

286

72

1 1/2"

1980

1160

2020

980

2204

78

15320

542

77

2"

2160

1110

1700

1260

2830

100

13200

467

77

2"

2160

1110

1700

1460

2700

95

10

9.5

145

100

136

75

125

125

55

90

90

IVR is tomorrows standard

compressor regulation