降低压缩空气能源费用LoweringCompressedAirEnergy课件.ppt

降低压缩空气能源费用LoweringCompressedAirEnergy课件
Benchmark Your System’s Efficiency
To make an accurate determination of energy savings solutions, it is important to measure your system flow, pressure and kW as well as evaluate any plans for future expansion This is accomplished by a flow and kW survey
250 CFM 2200 HRS/YR
B) 2nd shift
175 CFM 2200 HRS/YR
C) 3rd shift
100 CFM 2200 HRS/YR
75 HP unit @ 125 PSIG 82.5 Bhp full load power
320 CFM 91.5% Motor eff.
Within 12 months, the capital cost is usually exceeded by the running costs
First cost represents the lowest of the three costs
Energy consumption by far is the most significant factor in operating cost of an air compressor
100 CFM: 100/320 = 31% (79% Bhp) 100/290 = 34% (38% Input kW)
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Use Efficient Compressor Controls
75 HP lubricated screw with modulation control
60HP VSD @ 125 PSIG 66 Bhp full load power
290 CFM 94%
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Total KW Input
Performance Comparison
Total KW Input - vs- Capacity
• Benchmark your current system’s efficiency kWh/MCF
• Receive a detailed report outlining improvements
降低压缩空气能源费用LoweringCompressedAirEnergy课件
KW Meters
kWh
B) Second shift 175 CFM:
66 Bhp x .746 kW x (.61 factor) x $.06 x 2200Hrs = $4,217
.94 ME Hp
kWh
C) Third shift 100 CFM:
66 Bhp x .746 kW x (.38 factor) x $.06 x 2200Hrs = $2,627
(28% of installations).
time
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Energy Reduction Opportunities
• Use Efficient Compressor Controls • Reduce Compressed Air Usage • Lower Compressor Discharge Pressure • Efficiently Sequence Air Compressors • Operate and Maintain Compressed Air
A B
C D
A) Modulation Control B) Active Rotor Length Adj. C) Full Load / No Load D) VSD
10
20
30
40
50
60
70
80
% ity
降低压缩空气能源费用LoweringCompressedAirEnergy课件
80.0
75 HP w/ Upper range
70.0
modulation control
60.0
50.0
40.0
30.0 20.0
60 HP VSD
10.0
0.0 0
50
100
150
200
250
300
350
Capacity (CFM)
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Use Efficient Compressor Controls
60 Hp Variable Speed compressor
A) First shift 250 CFM:
66 Bhp x .746 kW x (.86 factor) x $.06 x 2200Hrs = $5,946
.94 ME. Hp
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Reduce Compressed Air Usage
• Eliminate inappropriate air users
• Use fans to cool electrical cabinets instead of compressed air vortex tubes
.94 ME Hp
kWh
Total = $12,790
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Use Efficient Compressor Controls
Total Power Savings:
$24,287 - $12,790 = $11,497 per year
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Benchmark Your System’s Efficiency
• Measure your compressed air requirements
– Flow – Pressure – Dew point – kW and kWh
Compressed Air Use in Selected Manufacturing Industries
Compressed Air Energy Use as a Percentage of Total Electricity Use
30 25 20 15 10
5 0
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Equipment at Peak Efficiency
降低压缩空气能源费用LoweringCompressedAirEnergy课件
% Power Input
100 90 80 70 60 50 40 30 20 10 0 0
Performance Comparison
Total KW Input -vs- Capacity
90
100
Use Efficient Compressor Controls
75 HP Lubricated screw compressor w/ Modulation Control -vs.- 60 HP VSD
Average electrical cost = $0.06 / KWHR
A) 1st shift
.915 Mtr. eff.
Hp kWh
C) Third shift
100 CFM:
82.5 Bhp X (.79 factor) X .746kW X $.06 X 2200Hrs =
.915 Mtr. eff.
Hp kWh
$7,422
Total = $24,287降低压缩空气能源费用LoweringCompressedAirEnergy课件
Life Cycle Cost of an air compressor
Installation Maintenance
Investment
Energy consumption
Energy cost can account for up to 90% over a ten year working life
降低压缩空气能源费用LoweringCompressedAirEnergy课件
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Typical 24
hrs/day
operation with
low night shift
and high day
shift
consumption.
60 HP VSD costs $25,000 for a 2.17 year payback!
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Reduce Compressed Air Usage
• Eliminate inappropriate air users • Use brushes, blowers, or vacuum systems instead of compressed air to clean parts or remove debris; • Use blowers, electric actuators, or hydraulics instead of compressed air blasts to move parts; • Use high efficiency nozzles instead of open orifices
A) First shift
250 CFM:
82.5 Bhp X (.93 factor) X .746kW X $.06 X 2200Hrs =
.915 Mtr. eff.
Hp kWh
$8,738
B) Second shift
175 CFM:
82.5 Bhp X (.865 factor) X .746kW X $.06 X 2200Hrs = $8,127
Use Efficient Compressor Controls
75 Hp modulating
60 Hp VSD
250 CFM: 250/320 = 78% (93% Bhp) 250/290 = 86% (86% Input kW)
175 CFM: 175/320 = 55% (86.5% Bhp) 175/290 = 60% (61% Input kW)
Why Care About Compressed Air?
• Compressed air is expensive • Compressed air is essential to plant productivity • Compressed air systems can be effectively
managed to improve plant operation • Compressed air systems usually have
significant opportunities for efficiency improvement
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Steady
weekend
consumption
(leakages).
time
(64% of installations).
降低压缩空气能源费用LoweringCompressedAirEnergy课件
降低压缩空气能源费用LoweringCompressedAirEnergy课件
Five days/week operation, erratic demand fluctuations
• Apply a vacuum system instead of using compressed air venturi methods
• Use blowers instead of compressed air to provide cooling, aspirating, blow guns, air lances, agitating, mixing, or to inflate packaging