Compressed Air System Optimization

Compressed air is often referred to as the fourth utility, along with electricity, oil/gas, and water. The cost of commpresed air like all utilities is not free and must be managed. Industry sources have estimated that the total connected horsepower of factory compressed air system in the U.S. exeeds 17 million. This represents a worthy target for the application of energy efficient technologies because many energy conscious engineers exposed to factor environments belive that from 10% to 35% of this could be saved. Using a national energy cost per kilowatt-hour of 8 cents, this translates to billions of dollars in operating cost reductions for the manufacturers. Hence, understanding of the trategies of optimizing the compressed air system is very important for energy engineers.

Components of a compressed air system

Compressed air systems consist of a supply side, which includes compressors and air treatment, and a demand side, wich includes distribution and storage system and enduse equipment. A properly managed supply side will result in clean, dry, stable air being delivered at te appropriate pressure in a dependable, cost-effective manner. A properly managed demand side minimizes wasted air and uses compressed air for appropriate applications. Improving and maintaining peak compressed air system performance requires addressing both the supply and demand sidesof the system and how the two interact.

A typical modern industrial compressed air system is composed of several major subsystems and many sub-components. Major subsystem include the compressor, prime mover, controls, treatment equipment and accessories, and the distribution system. The compressor is the mechanical device that takes in ambient air and invreases its pressure. The prime mover powers the compressor controls serve to regulate the amount of compressed air being produced. The treatment equipment removes contaminants from the compressed air and accessories keep the system operating properly. Distribution system are analogous to wiring in the electrical world-they transport compressed air to where it is needed. Compressed air storage can also serve to improve system performance and efficiency.

{source : Handbook of energy engineering by Albert Thumann,D. Paul Mehta}