Air Compressors

Two Types
Positive Displacement
Reciprocating

Rotary Screw

Dynamic
Centrifugal Axial flow

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T W O - CY LINDER, T W O - ST AG E CUT AW AY
,\SME-code interstage pressure relief valves. Graphite cylirider and

Valve design provides the highest One-piece aluminum valurietric efficiency in the rnari*Oace, head for Strength and using stainless-steel valves for optimum maloirn urn strength. heat dissipation.

head gaskets for posit** sealing integrity.

Coalescing aluminum mesh crankcase breather reduces oil %.'d Per.

Cast-Iron cylinder; main rigid tolerances for high efficiency

No-piece connecting rods make service easier.

-

High-poi a errem three-piece rirgs allay less than S. ppm oil carryover.

Pressure lubirlitaon 10 and 15 hp. models 45 and 7.5 hp crankshaft bearings onlA Electronically bakanced fan-type cast-iron flywheel del rmrS a powfui Plow of air across the intercooler, cylinder and heads for effective unit cooling and 51-myth operation

CHI level sight gauge.

High-efficiency fin and tube intercooler reduces rterstage air temporal's@ for rmaArliall perfornance and increased valve life

Geratar positive displacement pump (counter ciocictrise rctation on tyl

1fCast-iron C dependability o operaticn. m p i k e r

coristni and

aim or &moots

Lorroil level
assures lo PI oil temperaure, float cavity.

Industrlaklas5 bearings ensue long operating life.

Intake unloaders allow for Ioadless Cast-iron valve seats are lapped starting, system flexibility, energy for a total seal, eliminating savings, and less wear on the motor_ the need for a discharge line check valve.

Individual valve pockets allow easy access for routine maintenance. Steel valve discs use a unique low lift design and cast-iron bumpers for increased efficiency and less downtime

High pressure pistons

-

are cast-iron for strength and long life. Aluminum connecting rods with of passage for full flow lubrication to piston pins to extend compressor fife.

Cast-iron
maintain

cylinders

rigid tolerances

for high efficiency

Intercooler has large circular fins for maximum heat dissipation and longer He.

Hydraulic unloader and Safe-Q-Luibe protects compressor if oil pressure drops below normal when load less starting

or dual control is specified) _counter-weighted,

one piece crankshaft reduces

-

vibration, extends life of bearings and wrist pins .

Pressure lubrication with

positive displacement oil pump to assure

Tapered railer bearings are oversized and easily adjusted for trouble-free operation.

constant lubrication of all critical wear areas.

Castiron crankcase Spin-on oil filter

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and flywheel for strength for convenient, and durability. clean lubrication
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Rotary Screw Compressors

Rotary Screw Compressors

Direct Injection , Oil injected , Direct cooled, Flooded
Various names are suggestive of the direct contact of lubricating/cooling oil onto the rotating screw parts Requires a separator just after compression to remove oil from the compressed air

Oilfree, Oilless, Dry compressors also available (food industry, hospitals, etc.)

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

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

Due to overlapping and continuous compression cycles, the rotary screw design generates virtually no vibration. Disturbing noise is minimized, providing a wider choice for the unit's location on the vehicle.

The ends of the The air is As the rotors turn, Compressed air rotors uncover entrapped in the the compartment leaves through the the inlet: air 'compartment' becomes outlet port enters the formed by a male progressively smaller, compression lobe and a female thereby compressing chamber. flute. the entrapped air.

Centrifugal Compressors

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

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

Figure 1.1 Components of a Typical Industrial Compressed Air System.

Compressor Package Enclosure

Air Inlet Filter

Pressure/Flow Controller Distribution System

Pneumatic Tool

Control Panel

Compressor All End

Lubricant/Air Separator

illter, Regulator, andLubricator

Figure 1.1 Components of a Typical Industrial Compressed Air System.

Compressor Controls
On/Off (Start/Stop)

Modulated Load/Unoa l d Variable Displacement Variable Speed Drive (VSD)

PlantCompressedAirFIciNRateandSystemPIess-tir.

Plant Al Consumption

220 0
114 11.3 112 111

2000

Pie5.
311N.

J n

1200 1000

l
107 106

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15:35

i
15;45

:
15:50 15:55

800
0:10

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40)

105
15:30

15:40

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200 16;00

Flow to System SCFM)

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161:11:1

1400

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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

Amps 600

500

40 0 Curr_250_hp_rent (Amps) Curr_250_hp (Amps) Curr_100_hp (Amps)

300

200

100

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

Amps 400

300

200

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

100

Typical Compressor Controls/Characteristics

100 90 80 70 60 50 40 30 20 10 0
Powwer, percent of fu ull load

Start/Stop) (Load/Unload) Mod Mod/Unload

0 50 100
Capacity (Flow), percent

Compressors Saving Energy

Reduce run time turn off when not needed
Lower system pressure to lowest possible level Repar ileas k Recover waste heat Additional system volume (load/unload only)

Reduce use of pneumatic tools

Lower Pressure
Rule of thumb: For systems in the 100 psig range, every 2 psi decrease in discharge pressure results in approximately 1 percent power decrease at full output flow

Lower Pressure Lower Pressure Unregulated Usage

Rule of thumb: For systems with 30 to 50 percent unregulated usage, a 2 psi decrease in header pressure will decrease energy consumption by about 0.6 to 1.0 percent because of unregulated air Total is 1.6% to 2% power decrease for every 2 psi drop

Lower Pressure
Calculations
Estimate annual energy usage (assume compressor runs fully loaded unless you know otherwise) KWh = HP x 0.746 x LF x H Compute reductions: every 2psi reduction is a 1.6% to 2.0% reduction in power, so each 2psi reduction gives 0.984 to 0.98 of the previous value

Example Reduce Pressure

A 150hp compressor runs 90% loaded 12 hours per day 5 days per week at a delivery pressure of 110psi. Estimate the energy and cost savings if the pressure is reduced to 90psi. Assume $0.05/kWh for electricity. Solution: Assume a 1.8% reduction for every 2psi to account for unreguate l d usage. First estimate the annual energy usage:

Example/Solution Reduce Pressure

kWh= HP x 0.746 x LF x H

= 150hp x 0.746kW/hp x 0.9 x 3120 hrs

= 314,215 kWh/yr110 314,215 Compute reductions (Table at right)
108 308,559 =0.982*B1 106 303,005 104 297,551 102 292,195 100 286,936 98 281,771 96 276,699 94 271,718 92 266,827 90 262, 025

Energy Savings are 52,191 kWh/yr

Net reduction is 16.6%

At $0.05/kWh, this amounts to $2,610 / yr

Reduce Air Leaks

A typical plant that has not been well maintained will likely have a leak rate equal to 20 percent of total compressed air production capacity. Proactive leak detection and repair can reduce leaks to less than 10 percent of compressor output

Reduce Air Leaks

Calculations
Savings realized depend on the type of compressor controls Input power decreases linearly with decrease in airflow
Control Slope ( kW%/ cfm%)

Start/Stop 100/100

Mod 35/100

Unload 80/100

So for a 10% reduction in flow by repairing leaks

Control

Start/Stop
10%

Mod
3.5%

Unload
8%

kW%

Example Reduce Leaks

The compressor from the previous example uses modulating controls. The system reduces flow by 10% through a leaks program. Estimate energy and monetary savings at $0.05 per kWh. Solution: For a 10% reduction in flow, a 3.5% reduction i n power resuts: l

Example Reduce Leaks

Savings = 262,025 kWh/yr x 0.035

= 9,171 kWh/yr At $0.05/kWh, ts hicomes to Cost Savings = 9,171 kWh/yr x $0.05/kWh

= $ 459

Recover Waste Heat

As much as 80 to 93 percent of the electrical energy used by an industrial air compressor is converted into heat.

In many cases, a properly designed heat recovery unit can recover anywhere from 50 to 90 percent of this available thermal energy and put it to useful work heating air or water.
Net potential is 40% to 84% recovery

Example Recover Waste Heat

The compressor from the previous example is air cooled. Estimate the amount of natural gas heating that could be displaced during twelve weeks of winter operation, and the cost savings at 85% combustion efficiency and $4. 00 tu /MMBfuel cost. Solution: Assume 50% of the nput i power can e b recovered:

Example Recover Waste Heat

Savings = HP x 2545Btu/hp hr x 50% x H = 150hp x 2545Btu/hphr x 0.50 x (12wks x 5days/wk x 12hrs/day) x 1 MMBtu / 1E6Btu
= 137.4 u M t M B Cost Savings = Savings / EFF x FuelCost = 137.4 / 0.85 x 4.00 $ = $ 647

Examples Volume Additional Summary

Measure Energy Cost/Savings

Baseline operation Reduce Pressure

Repair Leaks Recover Waste Heat*

314,215 kWh/yr 52,191 kWh/yr

9,171 kWh/yr 40,270 kWh/yr (137.4 MMBtu/yr)

$15,711 /yr $ 2,610 /yr

$ 458 /yr $ 647 /yr

16.6%
2.9% 4.1%

TOTAL SAVINGS Energy

TOTAL SAVINGS Cost

101,632 kWh/yr
$ 3,715

32.3%
23.6%

*Assumes plant can use all available heat over a 12week period

Additional Volume

Additional Volume Additional Volume