Compressor

Air compressors work by taking in atmospheric air, reducing its volume via a mechanical piston or screw to increase pressure, and use for industrial equipment. Electric-powered compressors are widely used in production, workshops and garages with permanent access to electricity.

Worldwide , Compressor usages 400 TWh Electricity consumption and producing CO2 emissions of 400 Million Tonnes per year

Useful compressed air energy from compressor

The power of a compressor is measured in HP (horsepower) and CFM (cubic feet per minute of intake air)

During compressor operation, 85% of allied energy is losses in the form of

Heat losses 80 %

Mechanical losses 5 %

Only 15% is converted to useful compressed air energy.

Compressed air utilisation in conventional air system

It is observed that 50% of produced compressed air energy is wasted in the form of

1 - System losses ( 20%)

2 - Poor practise ( 20%)

3 - Artificial demand ( 10%)

Compressed air costing is high

Example: 500 CFM compressor usages 90kW motor at 70% load factor Content , Running 24 Hrs X 350 Days ; Electricity cost Rs 9.5/kWh

Electricity power required = 5,29,000 kWh /Year

Electricity energy cost: Rs 50L / Year

How to reduce wastage of air consumption in Industry

| Wrong selection of equipment | Air Motors
and Pumps | Pneumatic Grinder | Pneumatic
Drilling machines | Pneumatic Crane | | --- | --- | --- | --- | --- | | Action - Switch to an electric motor (whenever applicable) | Action - Switch to an electric tool | Action - Switch to an electric tool | Action - Switch to electric motor or hydraulic tool | | | System loss waste | Air leakage | Pressure loss across
filters, Dryer etc | | | | Action : Periodic checking of air leakage | Action : Flow measurement
and control | FAQs | FAQs
? How can I immediately reduce my compressed air energy costs?
- Reduce your system pressure. A reduction of just 2 psi cuts costs by 1%, while lowering pressure by 1 bar (
psi) can save approximately 7% in electricity.
- Fix air leaks. A 1 bar reduction also decreases the impact of air leaks by 13%.
? What is the best way to manage fluctuating air demand?
- Install a Variable Speed Drive (VSD) compressor, which adjusts motor speed to match air demand, eliminating
energy waste from idling.
? How does maintenance affect energy consumption?
- Dirty air filters, old oil, and clogged separators increase pressure drops, forcing the motor to work harder and wasting energy.
Clean or replace filters regularly.
? Can I save energy by using air from outside?
- Yes, for every ( ) rise in inlet air temperature, energy consumption increases by 1% for the same output. Using cooler air
intake improves efficiency.
? What is the benefit of a central controller?
- A central controller enables multiple compressors to run within a narrow pressure band, matching system needs precisely
and minimizing wasted energy.
? Should I turn off my compressor or dryer at night?
- Yes, shutting down equipment when not in use saves energy. However, refrigerated dryers may need 30 minutes to cool
down before production resumes.
? What is heat recovery in compressed air systems?
- Approximately 90% of electrical energy used by a compressor is converted into heat. A heat recovery system captures this
heat for space heating or hot water, increasing overall efficiency | |

Poor practise waste

| Action : Periodic checking of air leakage | Action : Flow measurement
and control | | | | | --- | --- | --- | --- | --- | | Artificial demand waste | High pressure
air system | Heavy
fluctuation demand | | | | Action : Use booster for high-Pr requirement equipment | Action : Use of Smart flow controller | | | | | Non standard operating condition | Poor Inlet air quality | High temp of
compressor room | Air Leakages
in machine | Air gun of wide spray | | Action : Use extra filter and dryer for purification level | Action : Maintain 2 deg C lesser temp than atmosphere | Action : Sectioning valve to close the supply during machine | Action : Choose air gun with efficient air nozzle | |