Compressed air energy savings in 4 moves

Transcription

1 Compressed air energy savings in 4 moves AEE NE Energy Marketplace Conference Andre L. Narbonne, PE, CEM, DOE-Qualified AIRmaster+ Specialist

2 20, HP COMPRESSOR COST YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 2

3 Typical air flow; Plastics plant 3

4 Capacity Control for rotary screw compressors > Modulation (Inlet valve restriction) > Least Efficient > Online/Offline (Full capacity/zero) > Better..but still consumes 25-35% power at zero flow > Variable volume (pretty good %) > Variable speed drive: (Load matching) > Most Efficient, close to linear performance 4

5 20,000 YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 MODULATION 5

6 20,000 MOVE ONE: CHANGE the curve YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 MODULATION 6

7 20,000 Move ONE: CHANGE the curve YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 MODULATION LOAD/NO-LOAD 7

8 Load/No-Load curve for OIL-injected compressors (Courtesy CAC sourcebook) 8

9 20,000 Move ONE: CHANGE the curve YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 MODULATION LOAD/NO-LOAD 9

10 20,000 Move ONE: CHANGE the curve YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 MODULATION LOAD/NO-LOAD VARIABLE SPEED DRIVE 10

11 20,000 Move ONE: Results YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 MODULATION: $84K LOAD/NO-LOAD: $72K VARIABLE SPEED DRIVE:$50K $34K SAVED by changing curves 11

12 20,000 Move 2: EXTEND the curve YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 VARIABLE SPEED DRIVE: $50K 12

13 YEARLY COST AT.13/KWH 20,000 00,000 $80,000 $60,000 $40,000 $20,000 Move 2: EXTEND the curve EXTEND the curve with premium efficiency compressor (more CFM per HP) 13

14 YEARLY COST AT.13/KWH 20,000 00,000 $80,000 $60,000 $40,000 $20,000 Move 2: Results EXTEND the curve with premium efficiency compressor (more CFM per HP) VARIABLE SPEED DRIVE: $50K PREMIUM VARIABLE SPEED DRIVE: $44K $6K SAVED by extending the curve SAVINGS: $40k 14

15 MOVE 3: DROP the curve DROP the curve 4% with lower pressure (10 PSI) YEARLY COST AT.13/KWH 15

16 YEARLY COST AT.13/KWH MOVE 3: Results DROP the curve 4% with lower pressure (10 PSI) 110 PSIG Operation: $44K 100 PSIG Operation: $42K $2K SAVED by dropping the curve SAVINGS: $42K 16

17 Move 4: DESCEND the Curve DESCEND the curve by demand reduction YEARLY COST AT.13/KWH 17

18 Move 4: DESCEND the Curve MOVE along the curve by 20% demand reduction YEARLY COST AT.13/KWH 18

19 YEARLY COST AT.13/KWH Move 4: RESULTS MOVE along the curve by demand reduction Before reduction: $42K After 20% reduction:$34k $8K SAVED by demand reduction TOTAL SAVINGS: $50k 19

20 NOTE > This example closely followed the complete implementations of a 150 HP machine in Worcester county 20

21 Putting it in practice >My compressor make 6 CFM/KW, so each CFM =0.16 KW >CORRECT? 21

22 20,000 Move ONE: CHANGE the curve YEARLY COST AT.13/KWH 00,000 $80,000 $60,000 $40,000 $20,000 MODULATION LOAD/NO-LOAD VARIABLE SPEED DRIVE 22

23 Four Moves > CHANGE the curve: improve part load e > EXTEND the curve: select premium e > DROP the curve: lower pressure > DESCEND the curve reduce demand 23

24 Thank you for attending! Open for questions/clarifications 24