1. Kaeser Compressors, Inc.
Compressed Air Efficiency Capturing and Sustaining Energy Savings
Wayne Perry
Technical Director
Kaeser Compressors, Inc.

2. US Department of Energy Estimates Half of all Compressed Air is Wasted
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3. Percent of Electricity Consumed by Compressed Air Systems
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4. If Compressed Air Systems Were Optimized
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5. Motor-Driven Systems are Initially Designed With
The assumption that “more” is better
Little or no thought given to system efficiency
No plan for increases or decreases in system demand
A “lowest first cost” goal
Changes to existing systems face the same issues
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

6. Proper Application of Variable Speed Compressors
Single unit
Trim compressor
Indoors
Varying demand
If demand is constant, multiple fixed speed compressors can be more efficient.
Multiple compressor system with a master controller
Where demand fluctuates between minimum and maximum output of the VSD
Free from dust and debris
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

7. Fixed Speed Compressor Operation
Operate between a defined pressure band
Typically idle for specific times between loads prior to shutting down and turning off
Typically base load compressors within a system
Recommend compressors with varying idle times
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

8. Fixed Speed Compressor Operation
Used in base load machines to avoid frequent motor starts
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9. Building a Compressed Air Station
Start with Demand Profile to find optimum combination of compressors
System Demand Flow Pattern
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10. Building a Compressed Air Station
Sample Compressor Operation
Multiple smaller units versus one larger unit:
High system efficiency over entire range
Lower overall capital cost to achieve system redundancy
Reduced lifetime costs
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11. Building a Compressed Air Station
Sample Compressor Operation
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12. Benefits of a Master Controller
Decouple compressors from demand
Optimize the efficiencies of all compressors
Maintain the lowest possible operating pressure for further energy reduction
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

13. Benefits of a Master Controller
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

14. Operating Pressure with a Master Controller
Properly applied master controllers:
Avoid cascading pressure bands
Reduce operating pressure to the lowest point possible
Anticipate demand events rather than react using timers
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

15. Operating Pressure with a Master Controller
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

16. Good Master Controller Can Provide
Up to one year’s worth of recorded data including:
Flow
Pressure
Load/Idle Cycles
Graphed Power Cost
Load/Idle Power
Specific Power
Tabular Power Costs
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

17. Benefits of System Optimization
Reduced energy consumption
Reduced maintenance expense
Reduced capital expense
Improved reliability of system components
Improved product quality
Improved productivity
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

18. System Optimization Case Study
Before System Optimization
After System Optimization
Savings
Plant
Avg. kWh/month
Avg. cfm/month %
Total kWh
Tons CO2 A
613,193
141,609,600
339,538
116,676,920
44.63
1,641,930
992 B
617,043
109,663,996
220,817
75,564,957
64.21
2,849,798
1,722 C
526,136
156,964,617
406,410
147,999,355
22.76
2,633,968
1,591 D
1,152,752
309,492,655
777,639
283,542,295
32.54
9,002,721
6,439 E
796,907
218,421,548
570,640
210,462,035
28.39
3,167,736
1,914
Compressed air specific power reduced from: kW/100 cfm to kW/100 cfm
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

19. Compressed Air as a Utility
Case study used a combination of optimization and outsourcing
Kaeser’s Sigma Air Utility is the leading provider of outsourced compressed air
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

20. Compressed Air as a Utility: How It Works
Company no longer purchases, maintains, or operates any compressors:
Energy management is assured
NO capital required
NO maintenance expenses
100% back-up of all critical components
© 2015 Kaeser Compressors, Inc., USA / V1.1 /

21. Compressed Air as a Utility: How It Works
Kaeser can install a Sigma Air Utility in new or existing compressor rooms.
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22. Compressed Air as a Utility: How It Works
If production space is at a premium, the Sigma Air Utility can also be “containerized”.
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23. Visit our booth for more information
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