Efficient Compressed Air systems - Portal GOV.SI

1

EU-Twinning Project SL04/EN/01Integrated Pollution Prevention and Control (IPPC)

Peter Radgen, Dr., STEFraunhofer Institute System and Innovation Research, Karlsruhe

Ljubljana, 13 -15 March 2006

Mission 6.2: Energy Efficiency

1

EfficientCompressedAir systems





2

80 TWh electricity consumption in compressed air systems in the EU-15

France12 TWh

Germany14 TWh

Italy12 TWh

Great Britain10 TWh

Rest of EU30 TWh

Portugal2 TWh

80 TWh = 80,000,000,000 kWh

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3

Worldwide Electricity Consumption in Compressed Air Systems (Total 400 TWh)

0,0

10,0

20,0

30,0

40,0

50,0

60,0

70,0

80,0

90,0

100,0

misc

ell. in

dustr

y

chem

ical in

dustr

y

stee

l indu

stry

non f

errou

s meta

ls

mac

hinery

pape

r and

pulp

Food a

nd Tob

acco

non m

etallic

mine

ral

texti

les an

d lea

ther

mini

ng

trans

port e

quipm

ent

woo

d

cons

tructi

on

Sector of Industry

Elec

tric

ity c

onsu

mpt

ion

in C

ompr

esse

d ai

r sys

tem

s [T

Wh]

EUROPE (W estern) EUROPE (Central & Eastern & FSU)AMERICA (North) AMERICA (Latin)AMERICA (South) AMERICA (Central)AMERICA (Caribbean) ASIA (East & South East)ASIA (South) AFRICA (North)AFRICA (Sub-Saharian) MIDDLE-EASTAUSTRALASIA

Dat

a fo

r 200

1

Most Important Sectors (share of 13 % each)

Textile and leather moreimportant in Asia

Paper and pulp more important in Europe and America





4

400 TWh electricity consumption in compressed air systems worldwide

400 TWh = 400,000,000,000 kWh

equal the electricity production of 110 coal fired power stations of 600 MW each and producing CO2emissions of 400 Million Tonnes per year

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5

Share of electricity consumption for compressed air for different sectors of industry

Sector

Share of electricity consumption for compressed air

low high Chemical industry 0.5 % 1.5 % Iron and steel 1.0 % 3.0 % Non ferrous metals (total) 0.5 % 5.0 % Aluminium 0.2 % 1.0 % Cement 0.5 % 9.0 % building materials 13.0 % 20.0 % Glas 15.0 % 30.0 % Ceramic 20.0 % 23.0 % Paper and board 4.0 % 9.0 % Food and tobacco (total) 5.0 % 10.0 % Breweries 4.0 % 9.0 % Dairy factory 4.0 % 7.0 % Industrial goods 10.0 % 20.0 % Wood and wood products 3.0 % 6.0 % Textile and leather 3.0 % 5.0 %

Source: IKARUS Datenbank, 1997; IKARUS Breitenerhebung, INRA, 1997; Ravel Handbuch Elektroantriebe, 1993; MURE II Datenbank, 1997, own calculations





6

Electricity for Compressed air and Energy cost on turnover

4009

0

500

1000

1500

2000

2500

3000

Food (1

5)

Tobacc

o (16)

Textile

(17)

Wearin

g appare

l, dres

sing (1

8)

Leather

(19)

Wood and

Wood

products

(20)

Pulp an

d Pap

er (21

)

Publis

hing and P

rintin

g (22

)

Coke a

nd petrole

um pro

ducts

(23)

Chemica

ls (24

)

Rubber

and Plas

tics (

25)

Non m

etallic

miner

als (2

6)

Basic

metals

(28)

Fabric

ated m

etal p

roducts

(28)

Machinery

and E

quipmen

t (29)

Office

mac

hinery

and c

omputers

(30)

Electri

cal m

achin

ery (

31)

Radio,

telev

ision, c

ommunic

ation (3

2)

Medica

l and o

ptica

l instr

uments

(33)

Motor veh

icles

(34)

Transp

ort eq

uipmen

t (35

)

Furnitu

res (3

6)

Recyc

ling (

37)

Elec

trici

ty c

onsu

mpt

ion

for

com

pres

sed

air [

1000

MW

h]

-4-3-2-1012345678

Ener

gy c

ost s

hare

in g

ross

out

put [

%]

Electricty for Compressed Air (Min.) Electricty for Compressed Air (Max.)Energy cost share on gross output [%]

4





7

Energy Saving Potential based on the EU Study

Energy savings measure % applicability (1) % gains (2) potentialcontribution (3)

System installation or renewalImprovement of drives (high efficiencymotors, HEM) 25 % 2 % 0.5 %

Improvement of drives: (Adjustable speeddrives, ASD) 25 % 15 % 3.8 %

Upgrading of compressor 30 % 7 % 2.1 %Use of sophisticated control systems 20 % 12 % 2.4 %Recovering waste heat for use in otherfunctions 20 % 20 % 4.0 %

Improved cooling, drying and filtering 10 % 5 % 0.5 %Overall system design, including multi-pressure systems 50 % 9 % 4.5 %

Reducing frictional pressure losses 50 % 3 % 1.5 %Optimising certain end use devices 5 % 40 % 2.0 %System operation and maintenanceReducing air leaks 80 % 20 % 16.0 %More frequent filter replacement 40 % 2 % 0.8 %

TOTAL 32.9 %Table legend: (1) % of CAS where this measure is applicable and cost effective

(2) % reduction in annual energy consumption(3) Potential contribution = Applicability * Reduction





8

Compressed Air System Requirements

• Reliability:nothing is more expensive than production standstills

• Highest compressed air quality:to avoid damages to machines, for product quality

• Low costs:no itemization of costs for producing compressed air, no responsibility for operation, lack of time and information

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9

More than 2/3 of all costs related to compressed air are related to energy consumption over the lifetime of the compressor

Energy cost78%

Investment cost16%

Maintenance cost6%

Assumptions:Power 110 kWEquipment life 15 aOperating hours 4000 h/aElectricity price 5 cent/kWh

Life Cycle Costs





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Life Cycle Costing

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11

Comparing Theory to PracticeResults of an CAS-Audit Campaign

0

10

20

30

40

50

60

70

80

90

100

10 100 1000 10000

Number of employees

spec

ific

savi

ng p

oten

tial [

%]

Source: Fraunhofer ISI, Karlsruhe, November 2003

0

10

20

30

40

50

60

70

80

90

100

1 10 100 1000 10000 100000

Electricity comsumption for compress air [MWh/a]sp

ecifi

c sa

ving

pot

entia

l [%

]Source: Fraunhofer ISI, Karlsruhe, November 2003





12

AssumptionsTurnover 10 Million $Return on Turnover 3 %Energy Cost 4 % of TurnoverElectricity accounts for 60 % of energy costsCompressed Air consumes 10 % of the electricity

Importance of cost savings

ResultIf the energy saving in the compressed air system is33 %, savings are worth 8,000 $.This is equivalent to an increase of turnoverof 2.6 % (266,666 $).

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Information providedFact sheets on• Thermodynamic

basics• Measurement

technology• Application• Production• Control• Treatment• Distribution• System optimisationhttp://druckluft-effizient/e/facts/fakten1.php





14

Heat Recovery by use of Cooling Air

Heated airduring summe

Heated air during heating season

Air intake Air intakewinter

Quelle: Druckluftseminar Druckluft effizient

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15

Heat recovery from an oil injected screw compressors

oil circuitcompressed air

cold waterhot water

Quelle: Druckluftseminar Druckluft effizient





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Heat exchangers for the use of compressor waste heat

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Profitability study for heat recovery

Tool shortly available in multiple languages at www.druckluft.ch





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Condensate Traps

manual

Mecanical floating trap

Time controlledmagnet valve

Electronic levelcontrolled trap

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19

Compressed Air Treatment and Compressed Air Quality Classes(use of refrigeration dryer)

Residual

0

0

0

0

1

3

4

4

Particles

0-1

0-1

0-1

0-1

0-1

2

3

4

Compressed air qualityclasses under ISO 8573-1

Humid, contamined airCentrally dried air

4

4

4

4

4

4

7

7

CompressorReceiver Refrig.

dryerDFACSF

D(S)F

D(S)F

DFAF

DF

SF

AF = activated carbon filterAC = activated carbon adsorberSF = surface filterDF = depth filterD(S)F = depth (sterile) filter

Residualwater oil





20

0-1

2

1

1

2

Particles

0

0

1

1

1

Residualoil

0-3

0-3

0-3

0-3

0-3

Residualwater

Compressed air quality classes under ISO 8573-1

Humid, contaminated airCentrally dried air

CompressorReceiver

Adsorptiondryer

DF AF SF

D(S)F

D(S)F

DF

SFAF = activated carbon filterSF = surface filterDF = depth filterD(S)F = depth (sterile) filter

Compressed Air Treatment and Compressed Air Quality Classes(Use of Adsorption Dryer)

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21

Measurement of compressed air demand by compressor operation

Intake Volume atTA ≈20°C

pA ≈ 1 bar (a)

Consumption during work freeweek-end Saturday = Leakagein this case 25 l/s = 1.5 m3/min

Significant demand increase when

production startsMaximum demand determines the power to be installed

Variation in demanddetermines system concept(Splitting and/or spped control





22

Production of Control Air(Monday 6.12.- Sunday 12.12.2004)

Control Air (Monday 6.12.04)

0

1000

2000

3000

4000

5000

6000

00:02

00:42

01:29

02:00

02:21

02:47

03:30

04:17

05:03

05:38

06:36

07:02

08:29

09:18

09:44

11:43

14:32

14:55

16:57

17:31

18:15

19:27

20:31

21:29

22:13

22:50

00:00

time

m3/

h

Champion 2Champion 1ZR 3-1ZR 4

Control Air (Thuesday 7.12.04)

0

1000

2000

3000

4000

5000

6000

00:02

00:39

01:31

02:15

02:53

03:51

04:23

04:52

05:32

12:09

12:38

13:10

13:48

14:32

16:42

17:37

18:29

19:19

19:59

20:51

21:52

22:27

23:14

time

m3/

h


Control Air (Saturday 11.12.04)

0

1000

2000

3000

4000

5000

6000

00:03

00:37

01:03

02:13

03:31

04:29

05:33

06:51

07:41

08:36

09:25

10:20

11:21

12:13

13:06

14:06

15:04

15:54

16:55

17:50

18:51

19:46

20:44

21:42

22:43

23:38

time

m3/

h


Control Air (Sunday 12.12.2004)

0

1000

2000

3000

4000

5000

6000

00:04

00:53

01:42

02:43

03:47

04:36

05:34

06:35

07:33

08:31

09:26

10:30

11:31

12:29

13:21

14:13

15:05

16:15

17:16

18:17

19:09

20:04

20:48

21:46

23:16

23:59

time

m3/

h


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23

Factory Air Balance of a Chemical Company (2004)

Factory Air Balance 2004

-800.000

-600.000

-400.000

-200.000

0

200.000

400.000

600.000

800.000

1.000.000

Janu

ary

Febr

uary

Mar

ch

Apr

il

May

June

July

Aug

ust

Sept

embe

r

Oct

ober

Nov

embe

r

Dec

embe

r

Volu

me

[Nm

3]

-60

-40

-20

0

20

40

60

Diff

eren

ce [%

]

Production including over flow control airConsumptionDifference





24

Annual Aggregated Control Air Consumption

Annual Aggregated Control Air Consumption

0

1000

2000

3000

4000

5000

6000

0 30 60 90 120 150 180 210 240 270 300 330 360days

Volu

me

[Nm

3/h]

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Comparison of Specific Electricity Consumption of the Compressors

0,050

0,060

0,070

0,080

0,090

0,100

0,110

0,120

0,130

0,140

0,150

0,160

0,170

0,180

0,190

0,200

0 5 10 15 20 25 30 35 40

F.A.D [m3/min]

spec

ific

cons

umpt

ion

[kW

h/m

3 ]

ZR4-AZR3-AZR-160 FChampionZR-160 VSD





26

Leakage Measurements

0,00

0,05

0,10

0,15

0,20

0,25

0,30

0,35

0,40

0,45

0,50

0,55

0,60

0,65

0,70

0,75

8:00

8:05

8:10

8:15

8:20

8:25

8:30

8:35

8:40

8:45

8:50

8:55

9:00

9:05

9:10

9:15

9:20

9:25

9:30

9:35

9:40

9:45

9:50

9:55

10:0

010

:05

10:1

010

:15

10:2

010

:25

10:3

010

:35

10:4

010

:45

10:5

010

:55

11:0

011

:05

11:1

011

:15

11:2

011

:25

11:3

011

:35

11:4

011

:45

11:5

011

:55

12:0

0

Volu

me

flow

(Nm

³/min

)

Nm³ based on DIN 1343, Pressure = 1013 mbar, Temperature = 0 °C, Humidity = 0 % rF.

Different Leakage Rates in Different Parts of the Plant

Different Leakage Rates in similar machines

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Faults identified during compressed air audits

Pocket filter reduce the free cross section of air intake opening Unnecessary spiral tubes

adding high pressure losses





28

Cyclone installed after filter

Compressor

Filter

Cyclone

Dryer

Storage Tank

Compressor

Cyclone

Dryer

Filter

Storage Tank

15





29


Warm air outlet located next to cold air intake





30

Compressor in dust loaded environment

Required inlet filter replacement not regularly made

16





31

Refrigeration dryer heated by compressor exhaust air





32


Where is the ducting ?

Spiral tube for what ?

17





33

„Creative“ solution to ventilate the compressor room ?





34

How to make compressor maintenance difficult

18





35

Oil Leakage from Compressor

Oil leakage from compressor





36

Long hoses to connect end use devices with the main line

K t ti 1

19





37

Compressed Air Distribution

Distribution networkwith wrong dimensions Water in the

distribution network





38

How audits pave the way to energy savings

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

replacement of compressor

replacement of air dryer

other changes at air treatment

reduction of leakage

redimensioning of piping

removal of bottlenecks

closing of network to rings

installation of electonic condensate traps

installation of sophisticated control

reduction of system pressure

organizational meassures

replacement of filters

additional meassurements

installion of electricity meter

installation of pressure sensor

installation of dew point sensor

economic calculations

call in for additional support

contracting

exchange to electromechanical drives

realised

in preparation

planned

What the companies have done or are planning to do after the audits

% of respondent

20





39

Benchmarking of Compressed Air Systems• Objective of benchmarking is to allow companies to compare their situation with

the systems of other companies and receive feedback about the success of implemented measures. Answering questions such as:

• Is the energy consumption of my compressed air system too high ?

• Are the maintenance costs of my system too high ?

• Where does my company stand in relation to others from the same sector ?

• Benchmarks are used for the analysis of production plants and are used as an effective instrument in corporate controlling.

• They compress an extensive amount of data into a comprehensible amount of key information. Benchmarks thus help management make decisions.





40

Compressed Air Indicatorscompressed air cost per Euro turnover

compressed air cost per employee

compressed air cost per m3

electricity consumption for compressed air per Euro turnover

electricity consumption for compressed air per employee

cost for electricity consumption per Euro turnover

share of electricity consumption for compressed air in total electricity consumption

specific power consumption for the compressor station

load factors of compressors

specific electricity consumption per m3 of air

number of malfunctions and repairs per operating hour

average age of compressors

installed compressor capacity per employee

size of storage capacity to installed compressor power

relation between electricity and fuel price

waste disposal cost per m3 of condensate

average percentage pressure loss in the distribution

maximum velocity in the main line

piping materials used

type of pipe connection used

length of distribution line per installed compressor power

type of dryers used types of condensate traps used

21





41

Internal BenchmarkingCost of Compressed Air per Turnover

Electricity cost dryer Electricity cost air compressors (work) Electricity cost compressors (power) Maintenance (internal and external) Repairs external Filter Condensate treatment and disposal





42

Internal BenchmarkingCost of Compressed Air per Number of Employees

Electricity cost dryer Electricity cost air compressors (work) Electricity cost compressors (power) Maintenance (internal and external) Repairs external Filter

Condensate treatment and dis-posal

22





43

Internal BenchmarkingCost of Compressed Air per Cubic Meter

Electricity cost dryer Electricity cost air compressors (work) Electricity cost compressors (power) Maintenance (internal and external) Repairs external Filter Condensate treatment and disposal





44

CAS System Load Factor

Comparison: NACE 25 Total Number of Values: 7Mean of Best (MB): 82 Mean of All (MW): 74

23





45

External Benchmarkingex. average age of compressor

Comparison: All sectors of industry Number of values: 160MB = Mean of Best; MW= Average Value





46

Use of Condensate Traps

= manual = time

= floating = electronic

Own company All companies

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47

Benchmarking

• Benchmarking is a cost effective measure to identify and quantify improvement potentials in CAS

• The Benchmarking can be used free of charge, removing a barrier for SME to check their systems without involving the high cost of an consulting engineer

• Benchmarking sensitize for the large economic energy saving potential in CAS

• Due to the further improvement underway the Benchmarking can be used also in all other countries (English and French Version will be available soon)

• CAS Consultants can help to realize the savings





48

Acknowledgments• The development of the Web-based Benchmarking for Compressed

Air Systems was supported by the German Ministry of Economics and Labour and 18 companies as part of the "Druckluft effizient" campaign.

• The continued maintenance and system adaptation to include multiple languages and currencies is actually supported by the Swiss Federal Office of Energy (SFOE) under contract No. 151 181.

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Efficient Compressed Air systems - Portal GOV.SI