降低压缩空气能源费用 Lowering Compressed Air Energy CostsPPT课件

1、Compressed Air Use in Selected Manufacturing IndustriesCompressed Air Energy Use as a Percentage of Total Electricity UseChemicalsPetroleumMetalsFoodPaper第1页/共52页Life Cycle Cost of an air compressorlEnergy cost can account for up to 90% over a ten year working lifelWithin 12 months, the capital cost

2、 is usually exceeded by the running costslFirst cost represents the lowest of the three costslEnergy consumption by far is the most significant factor in operating cost of an air compressorInvestmentInstallationMaintenanceEnergy consumption第2页/共52页lTo make an accurate determination of energy savings

3、 solutions, it is important to measure your system flow, pressure and kW as well as evaluate any plans for future expansionlThis is accomplished by a flow and kW survey Benchmark Your Systems Efficiency第3页/共52页 Measure your compressed air requirements Flow Pressure Dew point kW and kWh Benchmark you

4、r current systems efficiency kWh/MCF Receive a detailed report outlining improvementsBenchmark Your Systems Efficiency第4页/共52页KW Meters第5页/共52页第6页/共52页lTypical 24 hrs/day operation with low night shift and high day shift consumption. Steady weekend consumption (leakages). l(64% of installations).tim

5、e第7页/共52页第8页/共52页lFive days/week operation, erratic demand fluctuations l(28% of installations).time第9页/共52页Energy Reduction Opportunities Use Efficient Compressor Controls Reduce Compressed Air Usage Lower Compressor Discharge Pressure Efficiently Sequence Air Compressors Operate and Maintain Compr

6、essed Air Equipment at Peak Efficiency第10页/共52页Performance ComparisonTotal KW Input -vs- Capacity01020304050607080901000102030405060708090100A) Modulation ControlB) Active Rotor Length Adj.C) Full Load / No LoadD) VSDABCD% Capacity% Power Input第11页/共52页75 HP Lubricated screw compressor w/ Modulation

7、 Control -vs.- 60 HP VSDAverage electrical cost = $0.06 / KWHRA) 1st shift250 CFM2200 HRS/YRB) 2nd shift175 CFM2200 HRS/YRC) 3rd shift100 CFM2200 HRS/YR75 HP unit 125 PSIG60HP VSD 125 PSIG82.5 Bhp full load power66 Bhp full load power320 CFM 290 CFM91.5% Motor eff.94%Use Efficient Compressor Control

8、s第12页/共52页Performance ComparisonTotal KW Input - vs- Capacity0.010.020.030.040.050.060.070.080.0050100150200250300350Capacity (CFM)Total KW Input60 HP VSD75 HP w/ Upper range modulation control第13页/共52页Use Efficient Compressor Controls75 Hp modulating60 Hp VSD250 CFM: 250/320 = 78% (93% Bhp) 250/290

9、 = 86% (86% Input kW)175 CFM: 175/320 = 55% (86.5% Bhp) 175/290 = 60% (61% Input kW)100 CFM: 100/320 = 31% (79% Bhp) 100/290 = 34% (38% Input kW)第14页/共52页Use Efficient Compressor Controls75 HP lubricated screw with modulation controlA) First shift 250 CFM:82.5 Bhp X (.93 factor) X .746kW X $.06 X 22

10、00Hrs = $8,738.915 Mtr. eff. Hp kWhB) Second shift175 CFM: 82.5 Bhp X (.865 factor) X .746kW X $.06 X 2200Hrs = $8,127.915 Mtr. eff. Hp kWhC) Third shift 100 CFM:82.5 Bhp X (.79 factor) X .746kW X $.06 X 2200Hrs = $7,422.915 Mtr. eff. Hp kWh Total = $24,287第15页/共52页Use Efficient Compressor Controls6

11、0 Hp Variable Speed compressorA) First shift250 CFM: 66 Bhp x .746 kW x (.86 factor) x $.06 x 2200Hrs = $5,946.94 ME. HpkWhB) Second shift 175 CFM: 66 Bhp x .746 kW x (.61 factor) x $.06 x 2200Hrs = $4,217.94 ME HpkWhC) Third shift100 CFM:66 Bhp x .746 kW x (.38 factor) x $.06 x 2200Hrs = $2,627.94

12、ME Hp kWhTotal = $12,790第16页/共52页Total Power Savings:$24,287 - $12,790 = $11,497 per year60 HP VSD costs $25,000 for a 2.17 year payback!Use Efficient Compressor Controls第17页/共52页 System running with (2)-125 HP OL/OL compressors 3.7 kWH/MCF Inconsistent efficiencySystem running with (1)-125 HP OL/OL

13、 compressors and (1)-75 HP VSD3.3 kWH/MCFNearly constant efficiency第18页/共52页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 compr

14、essed air blasts to move parts; Use high efficiency nozzles instead of open orifices第19页/共52页Reduce Compressed Air Usage Eliminate inappropriate air users Use fans to cool electrical cabinets instead of compressed air vortex tubes Apply a vacuum system instead of using compressed air venturi methods

15、 Use blowers instead of compressed air to provide cooling, aspirating, blow guns, air lances, agitating, mixing, or to inflate packaging第20页/共52页Reduce Compressed Air Usage Minimize unregulated air users Install regulators Reduced pressure lowers air consumption Unregulated users use 47% more compre

16、ssed air at 110 vs. 70 PSIG Less equipment wear and tearAir PressureFlow ratePSIGSCFM5058.26067707680859094100103110112120121第21页/共52页Reduce Compressed Air Usage Shut off air to equipment that is shutdown or abandoned Install automatic solenoid valves Valve off idled sections of the plant第22页/共52页Re

17、duce Compressed Air Usage Fix Leaks Leaks can account for 10-50% of the total compressed air usage!1/8 inch dia. hole = 25 SCFM = $3,0001/4 inch dia. hole = 100 SCFM = $12,0003/8 inch dia. hole = 230 SCFM = $26,000* Based on 8,760 operating hrs/yr $0.07 per kWh energy cost第23页/共52页Reduce Compressed

18、Air Usage Minimize Leaks Measure leak load to quantify the opportunity Find the leaks with an ultrasonic leak detector Tag the leaks Fix the leaks Re-measure the leak load to quantify the savings Develop and on-going leak reduction program第24页/共52页Reduce Compressed Air Usage Reduce plant system air

19、pressure Unregulated air users and air leaks use 28% more compressed air at 120 vs. 90 PSIGAir PressureFlow ratePSIGSCFM5058.26067707680859094100103110112120121第25页/共52页Reduce Compressed Air Usage Reduce system air pressure Evaluate the pressure requirements of all compressed air users Put the small

20、 high pressure user on its own compressor Install good compressor sequencing controls Lower the system air pressure第26页/共52页Reduce System Air Pressure Measure system/component pressure drops Minimize distribution and component pressure drops Loop air header Upgrade, repair or eliminate high delta P

21、components Upsize piping/hoses Address large intermittent air “gulpers” that draw the system down with storage and metering valves Decentralize compressors第27页/共52页Receiver Sizing Useful Free Air Stored = V x P 14.7 V = storage volume (Ft3) P = pressure differential (Pressure Drop in Tank)Example: P

22、neumatic conveyor requires 200 cfm of 40 psig air for 2 minutes every 10 minutes. 200 X 2=400 CF required useful free air to be stored P= 100-40=60400=V X 60/14.7 V= 400 X 14.7/60 = 98 CF = 735 gallons400 CF/8 minutes=50 CFM to refillSystem sees 50 CFM instead of 200 CFM!第28页/共52页Lower System Pressu

23、re to Lower Air Consumption70 psig 700 CFM air usage85 psig 825 CFM air usage95 psig 950 CFM air usage第29页/共52页Reduce Compressed Air Usage Reduce system air pressure Use intermediate controllers with storage to regulate system air pressure Effective when part of the plant operates at a lower pressur

24、e Lowers air consumptionDoes not lower compressor pressure第30页/共52页Reduce Compressed Air Usage Reduce system air pressure Use effective compressor sequencing, storage, and compressor controls to “regulate” system pressureLowers air consumption and compressor pressureMost energy efficient第31页/共52页Seq

25、uence Air Compressors第32页/共52页Typical System Without a SequencerCascading SystemsC1C2C3C4unloadloadlIndividual settingslLarge pressure bandlMultiple units at part loadlVery inefficient100 PSIG110105115110120115125 PSIG125100第33页/共52页Sequencers Significantly Improve Efficiency to Minimize Energy Cost

26、s Can regulate system pressure within 3-5 psi Lower system pressure significantly reduces air demand (leaks and unregulated demand) Operates the minimum # of compressors to meet the demand Only one compressor trims at all times Automatic scheduled system pressure changes and/or start/stop of system

27、Most efficient compressor sequence order determined from flow data Can automatically select optimum sequence第34页/共52页System Pressure remains consistent as flow rate varies第35页/共52页Power consumption increases 1% for every 2 psi increase in compressor pressure RULE OF THUMB第36页/共52页EXAMPLE- 4-100 Hp C

28、ompressors Required: 1700 SCFM at 100 Psig Pressure Switch Settings Between 95 to 125Psig Pressure Band of 30 Psig 400 Hp x .745 kW/Hp x 8800/year x .06 kWh = $167,387.00.94 (motor Efficiency)Reduce Pressure Band by 25 Psig to save 12%=$20,086.00 Sequencers pay for themselves in energy savings by re

29、ducing pressure band differentials and lowering air usage第37页/共52页Flow changes but kW does not change proportionally02004006008001000120014001600180016111621263136414651566166717681869196101106111116121126131136MEC_SCFMTotal Kw第38页/共52页Poor efficiency of a cascaded system due to multiple units at pa

30、rt loadkWh/100CF-0.10.10.30.50.70.91.11.31.51.00954.001907.002860.003813.004766.005719.006672.007625.008578.009531.0010484.0011437.0012390.0013343.0014296.0015249.0016202.0017155.0018108.0019061.0020014.0020967.0021920.0022873.0023826.0024779.0025732.0026685.00kWh/100CF第39页/共52页Sequencers Can Signif

31、icantly Improve Efficiency to Minimize Energy CostsTotal system energy savings of 20-50% are expected 第40页/共52页kW/100 CF stays consistent even under varying loads.32 kW/100CF versus .85 kW/100CF (63% Savings!) 第41页/共52页 Switch to LILO Sequencing with a 5 minute unloaded time第42页/共52页Total Anual Savi

32、ngs!$15,347$30,695$122,778$61,389$0$20,000$40,000$60,000$80,000$100,000$120,000$140,000100200400800Total System HorsepowerSequencing Significantly Improves Efficiency to Minimize Energy CostsBasis 3 shift operation, $.06/kWhr, 20 PSI pressure band reduction% Savings100200400800Tighter Pressure Band1

33、0%$4,235$8,471$16,941$33,883Reduced Unregulated Demand/Leaks6%$2,541$5,082$10,165$20,330More Efficient Sequencing20%$8,471$16,941 $33,883$67,766Total Estimated Savings!36%$15,347$30,695 $61,389 $122,778Total System Horsepower 第43页/共52页 System flow and pressure are logged automatically Determine the

34、most efficient compressor sequence Useful for peak load shedding Measure leaks Spot system/ production problems Measure equipment/process air consumptionAdvanced sequencers provide system flow and pressure data to manage your 4th Utility第44页/共52页 ManagAIR by Air Technologies System Report for Ferro

35、9/7/01 1:59:05 PMAlarm: No Faults DetectedCurrent System Readings- Pressure=108 Flowrate=1347 Sequence=2,1,3Previous 8hrs Data: Hour1 Hour2 Hour3 Hour4 Hour5 Hour6 Hour7 Hour8 Min Pressure 104 104 104 104 104 104 104 104Avg Pressure 108 108 109 109 109 109 109 109Max Pressure 114 114 114 114 114 114

36、 114 114Min FlowRate 1274 1274 1311 1322 1324 1349 1311 1305Avg FlowRate 1448 1468 1648 1647 1739 1870 1644 1718Max FlowRate 2274 2298 2504 2485 2545 2629 2409 2432Min DewPoint -44 -43 -43 -43 -40 -36 -32 -21Avg DewPoint -41 -41 -36 -40 -37 -33 -25 -15Max DewPoint -39 -39 -11 -37 -35 -30 -19 -10Comp

37、ressor Data #1 ZT25 #2 ZT25 #3 ZT25 NONE NONE NONE NONE Delivery Air Press 110 113 107 DP Air Filter -.01 -.1 .01 Intercooler Pressure -9 30 1 Oil Injection Press 28 28 0 Delivery Air Temp 93 93 86 Oil Injection Temp 122 124 90 LP Outlet Temp 351 352 95 HP Outlet Temp 363 372 91 HP Inlet Temp 99 104

38、 91 Cooling Medium Inlet Temp 91 91 86 MD Regen Air Out Temp 129 162 84 MD Wet Air In Temp 97 99 81 LP Element Temp Rise 260 261 9 HP Element Temp Rise 264 268 0 Cooling Water Temp Rise Oil Cooler Approach Temp 31 33 4 Aftercooler Approach Temp 2 2 0 Intercooler Approach Temp 8 13 5 MD Regen Temperature Drop 234 210 7 MD Inlet Temperature Diff 4 6 -5 Loaded Hours 7358 7579 8773 Running Hours 11048 11616 12606 Compressor Status UNLOADED LOADED STOPPED Motor Starts 1717 1042 1060 Link Type MKIII MKIII MKIII Isolated/Integrated CENTRAL CENTRAL CENTRAL Full Feature Dew Point Oil Filte