Best Practices from the U.S. Department of Energy

In the U.S. industrial sector, compressed air systems account for an estimated $5 billion per year in energy costs. Many industries use compressed air systems as power sources for tools and equipment used for pressurizing, atomizing, agitating, and mixing applications. Optimization of compressed air systems can provide energy efficiency improvements of 20%-50%.

Effect of Intake on Compressor Performance
The effect of intake air on compressor performance should not be underestimated. Intake air that is contaminated or hot can impair compressor performance and result in excess energy and maintenance costs.

Minimize Compressed Air Leaks
Leaks are a significant source of wasted energy in a compressed air system, often wasting as much as 20%-30% of the compressor’s output. Compressed air leaks can also contribute to problems with system operations, including: fluctuating system pressure, excess compressor capacity, resulting in higher than necessary costs, decreased service life and increased maintenance of supply equipment.

Determining the Right Air Quality for Your Compressed Air System
Knowing the proper air quality level required for successful production is an important factor in containing compressed air energy and other operating costs, because higher quality air is more expensive to produce.

Determine the Cost of Compressed Air for Your Plant
Most industrial facilities need some form of compressed air, whether for running a simple air tool or for more complicated tasks such as the operation of pneumatic controls. A recent survey by the U.S. Department of Energy showed that for a typical industrial facility, approximately 10% of the electricity consumed is for generating compressed air.

Analyzing Your Compressed Air System
The first step in analyzing a compressed air system is to determine your compressed air needs. Assessing these needs carefully and understanding the difference between air quality and air quantity will ensure that a compressed air system is configured properly.

Preventive Maintenance Strategies for Compressed Air System
Like all electro-mechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak efficiency and minimize unscheduled downtime. Inadequate maintenance can increase energy consumption via lower compression efficiency, air leakage, or pressure variability. It also can lead to high operating temperatures, poor moisture control, excessive contamination, and unsafe working environments.

Compressed Air System Control Strategies
Improving and maintaining compressed air system performance requires not only addressing individual components, but also analyzing both the supply and demand sides of the system and how they interact, especially during periods of peak demand.

Stabilizing System Pressure
Stabilizing system pressure is an important way to lower energy costs and maintain reliable production and product quality. The need to stabilize system pressure should be guided by the compressed air demand patterns and the minimum acceptable pressure level required for reliable production.

Compressed Air Storage Strategies
Compressed air storage can allow a compressed air system to meet its peak demand needs and help control system pressure without starting additional compressors.  The appropriate type and quantity of air storage depends on air demand patterns, air quantity and quality required, and the compressor and type of controls being used.

Engineer End Uses for Maximum Efficiency
Ensuring an appropriate, stable pressure level at the end-use applications is critical to the performance of any industrial compressed air system. End uses that are engineered for maximum efficiency can help provide the consistent supply of compressed air that ensures reliable production.

Maintaining System Air Quality
Maintaining the proper air quality level is essential for keeping compressed air energy costs down and to ensure reliable production. Poor air quality can have a negative effect on production equipment and can increase energy consumption and maintenance needs.

Remove Condensate with Minimal Air Loss
Removing condensate is important for maintaining the appropriate air quality level required by end uses. However, significant compressed air (and energy) losses can occur if condensate removal is done improperly.