THE REAL COST OF COMPRESSED AIR

2015 WEA Conference

Presented by Jeff Treble

COMMITTED TO SUSTAINABLE PRODUCTIVITY

We stand by our responsibilities towards our customers, towards the environment and the people around us.We make performance stand the test of time. This is what we call – Sustainable Productivity.

Compressor Air Technologies

Air Compressor Lifecycle Costs

Variable Speed Drive

Onsite Nitrogen Generation

THE REAL COST OF COMPRESSED AIR

COMPRESSOR TECHNOLOGIES

COMPRESSED AIR TECHNOLOGIES

Oil-injectedscrew compressors

Oil-free piston compressors

Oil-injected pistoncompressors

Oil-free water-injected screw compressors Oil-free tooth

compressors

Purchased products

Filters

Compressor controls

Oil-free scroll compressors

Desiccant dryers

Refrigerant dryersMembrane dryers

Oil/water separators

Drains

Active carbon filter

Membrane nitrogen

generators

PSA nitrogen generators

PSA oxygen generator

Oil-sealed rotary screw vacuum

pumps Oil-sealed rotary vane vacuum

pumps

COMPRESSOR TECHNOLOGIES

AIR COMPRESSOR LIFECYCLE COSTS

AIR COMPRESSOR LIFE CYCLE COSTSInvestment, Maintenance & Energy

Inbuilt Water Separator Automatic

Water Drains

70%

15%

15%

Energy

Maintenance

Investment

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Condensate Treatment

Integrated Dryer

Inbuilt Water Separator Automatic

Water Drains

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Condensate Treatment

Integrated Dryer

Inbuilt Water Separator Automatic

Water Drains

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Oil Carryover

Oil Separator Vessel

Lubricants

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Oil Carryover

Oil Separator Vessel

Lubricants

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Sound Attenuation

Oil Separator

70dB(A)

3db(A) Sounds Twice as Loud!

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Sound Attenuation

Oil Separator

70dB(A)

3db(A) Sounds Twice as Loud!

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Drive Type

Belt Drive Direct Drive

Motor Element

Gearbox Drive

Efficiency

Capital Cost

AIR COMPRESSOR LIFE CYCLE COSTSInvestment: Compressor Performance vs. Efficiency

Free Air Delivery

Specific Energy

Requirement

365385405425445465485505525

1000 2000 3000 4000 5000 6000 7000 8000

SER

(J/l)

SPEED (RPM)

SER Performance (7BAR)

AIR COMPRESSOR LIFE CYCLE COSTSService

Maintenance Plans

Genuine Parts

PreventativeMaintenance

Plan

Ad-hocServing

TotalResponsibility

Plan

AIR COMPRESSOR LIFE CYCLE COSTSService

Maintenance Plans

Genuine Parts

Every 1 Bar in pressure drop equates to 7%increase in energy consumption. Consider a75kW compressor that uses 80kW consistentlyover 8,000 hours, with electricity cost of 25cents per kilowatt hour. 1 Bar pressure drop =$11,200 per year

AIR COMPRESSOR LIFE CYCLE COSTSEnergy

The yearly electrical cost of operatinga 75kW compressor that uses 80kWconsistently over 8,000 hours, withelectricity cost of 25 cents per kilowatthour is $160,000!

Air Demand Profile n°1

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Air Demand Profile n°2

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Air Demand Profile n°3

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AIR COMPRESSOR LIFE CYCLE COSTSData Logging and Simulation

Take measurements of the system

Download data from M-Box Do SimulationsLoad profile

AIR COMPRESSOR LIFE CYCLE COSTS

Correct Sizing of compressor

Accurate simulation of alternate technology

Guaranteed energy savings

Data Logging and Simulation

Measured Against Actual Use

VARIABLE SPEED DRIVE

VARIABLE SPEED DRIVETraditional Compressors Generate Losses

VARIABLE SPEED DRIVE

Compressor Speed regulates to keep up with Demand– Eliminates Blow Off and Unloaded Losses

Keeping up with demand

VARIABLE SPEED DRIVE

Average saving 35% of energy– 35% x $160,000 = $56,000

Must Check!– Turn Down Ratio at least 80%– Oil Separator does not blow off– Hi Torque Motor– VSD Motor Bearings– Integrated Design– Adjustable Pressure

Traditional VSD

VARIABLE SPEED DRIVE

Average saving 50% of energy– 50% x $160,000 = $80,000

Same Benefits as traditional VSD except:– Uses highly efficient Oil Cooled Permanent

Magnet Motor, IP66– Optimised element Design– Direct Drive– Optimised Inlet valve– Smaller Cooling Fan– Smaller footprint– Lower noise levels

Next Generation VSD

ONSITE NITROGEN GENERATION

ON SITE NITROGEN GENERATION

Benefits of onsite generation– Cost– Self Reliance– Occupational Health and Safety– Continuous Supply

It’s time to wean yourself off the bottle

Nitrogen

Oxygen

Argon

Hydrogen

Neon

Helium

Kripton

Xenon

Carbon Dioxide

Gas Type Volume %

78,08

20,94

0,93

0,0005

0,0019

0,0005

0,0001

0,000008

0,02-0,04

ON SITE NITROGEN GENERATION

Membrane– Compressed Air Passes through membrane chamber– Because of molecule size

Oxygen permeates through membrane wallNitrogen rich air Flows through membrane

Pressure Swing Absorption– Compressed Air passes through CMS Chamber– Because of molecule size

Oxygen molecules attach to CMSNitrogen rich air Flows through CMS

Technology

ON SITE NITROGEN GENERATIONGenerate Nitrogen on Site and $ave

COMMITTED TOSUSTAINABLE PRODUCTIVITY.