Operational Optimization of Compressed Air Networks
Compressed Air
Measure Goal
The goal of this document is to calculate the electricity savings achieved through operational optimizations of a compressed air network.
Symbols, Terms and Units
| Symbol | Description | Unit |
|---|---|---|
E | annual electricity consumption | kWh/a |
ΔEeco | cumulative electricity savings | kWh |
n | number | — |
Ns | standard effective duration | a |
f | factor | — |
Ė | electrical rated power (motor) | kW |
L | leakage quantity | l/min |
Δp | operating pressure difference | bar |
t | full load hours | h/a |
Calculation Formulas
Creditable Savings
The creditable electricity savings of the measure is the difference between the current and the new annual electricity consumption, cumulated over the standard effective duration. To account for the natural renewal and optimization rate, the creditable electricity savings are reduced by a reduction factor f_eco of 0.75. The standard useful life is 3 years.
Leakage Optimization (Flat-rate Approach)
For each leak remedied, the savings factor f_eco,lk of 0.2% can be summed. The savings factor is limited to a maximum of 3%.
Leakage Optimization (Analysis)
The leakage quantity is measured with a leakage measuring device. The specific electrical power Ė_spez is determined based on the operating pressure (4-15 bar, 5.12-10.1 kW/m³/min). The individual measure is limited to a maximum of 20% savings.
Network Optimization (Pressure Reduction)
A 1 bar reduction in operating pressure can trigger energy savings of 6%. The savings factor f_eco,dp is 6%. The individual measure is limited to a maximum of 20% savings.
Network Shutdown
The leakage losses across the entire compressed air network average 15%. The savings factor f_eco,ab is 15%. The network shutdown can be manual or automatic with time control.
Examples and Scenarios
Leakage analysis and remediation: A leakage analysis is carried out for an 8 bar compressed air network and a leakage quantity of 250 l/min is found and remedied. The full load hours are 6,000 h/a with an annual electricity consumption of 150,000 kWh/a.
Inputs
250 l/min leakage, 8 bar network
Flat-rate approach leaks: 25 possible leaks in the operation are remedied. The leakage share would thus be 5%, but a maximum of 3% is credited with an annual electricity consumption of 150,000 kWh/a.
Inputs
25 leaks fixed (3% factor)
Pressure reduction: The operating pressure of a compressed air network is reduced by 2 bar with an annual electricity consumption of 300,000 kWh/a. A 1 bar reduction can trigger 6% energy savings.
Inputs
Reduction by 2 bar (12% factor)
Network shutdown: The compressed air compressor is now switched off on weekends and at night by a timer. 100% of the network is disconnected for 3,500 h/a with an annual electricity consumption of 300,000 kWh/a. The leakage losses across the entire compressed air network average 15%.
Inputs
Timer (3,500 h/a, 100% network)
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