November 7, 2012 by kaeserusa
1. Turn off compressors when not needed.
A 100 hp compressor can cost $75,000 per year in energy costs (based on 8,760 hours at .10 per kWh).
2. Identify and fix air leaks.
Studies show that anywhere from 25-50% of all compressed air generated is wasted to leaks!
3. Eliminate inappropriate uses of compressed air.
Using compressed air for blow off is not only wasteful, it can be dangerous as well. Did you know that using air over 30 psi for blow-off is actually an OSHA violation?
4. Apply proper controls to multiple-compressor systems.
Master system controls maintain a stable system pressure and ensure that only the needed compressor units brought online and that they are operating at peak efficiency.
5. Ensure piping and storage are adequately sized.
Many systems lack adequate storage. Kaeser recommends both a “wet” and “dry” tank. Undersized piping will increase pressure drop in the system.
6. Change your filters routinely to eliminate pressure drop.
Every 2 psi in pressure drop costs 1% in compressor horsepower efficiency.
7. Use automatic, zero-loss condensate drains.
Capacitance sensor operated drain traps don’t need to be monitored. They discharge only condensate not valuable compressed air.
8. Apply variable speed drive compressors where appropriate.
Variable speed drive is not a one-size fits all solution. But if you have varying demand, it can save you thousands on electricity costs each year.
9. Reduce operating pressure to lowest possible setting.
For every 2 psi reduction in system operating pressure, you save 1% in compressor efficiency.
10. Recover waste heat from coolers.
A 50 hp compressor rejects heat at approximately 126,000 Btu per hour. What could you do with that heat?
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Michael Camber is currently Kaeser’s Marketing Services Manager. He has been in a number of sales, marketing and training roles since joining Kaeser in 1997. Michael is a member of Kaeser’s active training team, educating both Kaeser’s distribution network and customers on reliable and energy efficient compressed air system design.