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Air Compressor Optimization

Like all electro-mechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak effi
Inadequate maintenance can increase energy consumption via lower compression efficiency, air leakage, or pressure variabil
temperatures, poor moisture control, excessive contamination, and unsafe working environments. Most issues are minor and
cleaning, part replacement, or elimination of adverse conditions.

This tool calculates the energy savings associated with making minor changes to your air compressor system. Each tab calcu
the following changes:
Use outside air for air compressor intake
Reduce compressor air pressure
Repair compressed air leaks
Use synthetic lubricant in compressors
Recover waste heat from air compressor and use it to heat the plant in the winter
Use vortex nozzle for cleaning

Enter the data specific to your compressor in the section labeled Compressor Data. These inputs are shared by the six tabs b
inputs specific to the changes listed above. The cumulative savings for implementing all the changes is calculated at the botto

Air Compressor Optimization Calculator


General Inputs
Number of Compressors
Horse Power
Efficiency

91.5 %

Load Factor

0.84

Operating Hours

hrs

Cost of Electricity

$/kWh

Current Energy Consumption

kWh

Additional Resources

The US DOE Energy Management Portal: https://save-energy-now.org


The US DOE Compressed Air site: http://www1.eere.energy.gov/industry/bestpractices/compressed_air.htm
The US DOE Compressed Air Tip Sheets: http://www1.eere.energy.gov/industry/bestpractices/tip_sheets_c
The Compressed Air Challenge: http://www.compressedairchallenge.org/
Acknowledgement

This tool was created by the West Virginia University Industrial Assessment Center. For more information abo
visit their website www2.cemr.wvu.edu/~wwwiac/.

ressor Optimization

equire periodic maintenance to operate at peak efficiency and minimize unscheduled downtime.
ression efficiency, air leakage, or pressure variability. It also can lead to high operating
working environments. Most issues are minor and can be corrected with simple adjustments,

ges to your air compressor system. Each tab calculates the energy savings associated with one of

n the winter

or Data. These inputs are shared by the six tabs below this section. Each tab requires additional
ementing all the changes is calculated at the bottom of the tool.

Utilization Factor
N Value

1.25

Current Operating Pressure

psig

Maximum Rated Pressure

psig

Atmosphere Pressure

14.7 psig

Demand Cost

$/kWh/mo

-now.org
ov/industry/bestpractices/compressed_air.html
nergy.gov/industry/bestpractices/tip_sheets_compressed_air.html
allenge.org/

Assessment Center. For more information about the WVU Industrial Assessment Center,

Reduce Air Pressure


Air Temperatures
Current Discharge Pressure
Proposed Discharge Pressure
Implementation Details
Labor Hours for Pressure Adjustment
Labor Rate
Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

$
$
$

psig
psig

$/hr

kWh
kW

Lbs

kWh

Outside Air
Air Temperatures
Current Average Intake Temperature
Average Outdoor Temperature

51

Implementation Details
Total Feet of Duct
Number of Elbows
Cost of Duct
Cost of 1 Elbow
Labor Hours
Labor Rate
Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

$
$
$

F
F

ft
$/ft
$
hrs
$/hr

kWh
kW

Lbs

kWh

Synthetic Lubricants
Implementation Details
Cost Difference per Gallon
Gallons Required
Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

$
$
$

gallons

kWh
kW

Lbs

kWh

Waste Heat
Waste Heat
Cost of Fuel
Number of Months Plant Required Space Heating
Savings
Annual Energy Savings
Annual Energy Savings
Total Annual Cost Savings
CO2 Savings

Current Energy Consumption

$/MMBtu

kWh
MMBtu
Lbs

kWh

Vortex Nozzle
Vortex Nozzle
Number of Vortex Nozzles
Compressed Air Usage Factor
SCFM from Nozzle
Operating Period of Nozzle
Usage Factor of Nozzle
Implementation Details
Cost per Nozzle
Labor Time per Nozzle
Labor Rate
Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

$
$
$

min/day

hrs
$/hr

kWh
kW

Lbs

kWh

Air Leaks
Air Temperatures
Line Pressure at the Leak
Average Line Temperature
Current Average Intake Temperature
Number of Air Leaks
Average Size (Diameter)
Implementation Details
Total Feet of Duct
Number of Leaks per year
Cost to Fix a Leak
Labor Hours to Fix a Leak
Labor Rate
Savings
Annual Energy Savings
Demand Savings
Annual Energy Cost Savings
Annual Demand Cost Savings
Total Annual Cost Savings
CO2 Savings
Implementation Cost
Total Cost of Implementation

Current Energy Consumption

$
$
$

psig
F
F
in

ft

hrs
$/hr

kWh
kW

Lbs

kWh

Instructions for using the Air Compressor Tool


1

Enter the general inputs on the first tab. All fields must be filled in.

2
3

Enter input values into the 6 tabs (Outside Air, Reduce Air Pressure, Synthetic Lubricants, Waste Heat
Air Leaks). All of the tabs do not need to be filled in.
Results will appear in the grey section of each tab.

Key
Utilization Factors
Load Factors
Efficiency
Maximum Rated Pressure
Current Operating Pressure
Atmospheric Pressure

N Value

the Air Compressor Tool

the first tab. All fields must be filled in.

6 tabs (Outside Air, Reduce Air Pressure, Synthetic Lubricants, Waste Heat, Vortex Nozzles, and
o not need to be filled in.
ey section of each tab.

Key
The maximum demand of a system divided by its rated capacity.
The average power divided by the peak power over a period of time.
Enter the efficiency of your system as a decimal value between 0 and 1.
The maximum pressure at which the manufacturer determines it is safe to operate the
nozzle.
The pressure the compressed air system is currently operating at.
If unknown, use the default value of 14.7 psig.

Compression factor based on type of compressor and polytropic efficiency. Use the
following list to determine the N-value for your system.
N = 1.25 for screw compressors with polytropic efficiency of 80%
N = 1 for reciprocating compressor with single stage
N = 2 for reciprocating compressor with double stage