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 0.10 per kWh.
2. Identify and fix air leaks.
An estimated 25-50 percent of compressed air generated is wasted due to leaks.
3. Eliminate inappropriate uses of compressed air.
Using compressed air for blow off is not only wasteful, it also can be dangerous. Using air over 30 psi for blow-off is an OSHA violation.
4. Apply proper controls to multiple-compressor systems.
Master system controls maintain stable system pressure and ensure that only the needed compressor units are brought online and are operating at peak efficiency.
5. Ensure piping and storage are adequately sized.
Many systems lack adequate storage. Both “wet” and “dry” tanks are recommended for usage. Undersized piping will increase the pressure drop in the system.
6. Change your filters routinely to eliminate pressure drop.
Every 2 psi in pressure drop costs 1 percent 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 for varying demands, it can save thousands on electricity costs each year.
9. Reduce operating pressure to lowest possible setting to save energy.
For every 2 psi reduction in system operating pressure, you can save 1 percent in compressor efficiency.
10. Recover waste heat from coolers.
A 50-hp compressor rejects heat at approximately 126,000 Btu per hour.
Source: Kaeser Compressors. For information visit us.Kaeser.com
For a list of air compressor suppliers, visit RedBookOnline.com
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