Modeling of Industrial Air Compressor System Energy Consumption and Effectiveness of Various Energy Saving on the System

Abstract

The purpose of this research is to analyze the overall energy consumption of an industrial compressed air system, and identify the impact of various energy saving of individual subsystem on the overall system. Two parameters are introduced for energy consumption evaluation and potential energy saving: energy efficiency (e) and process effectiveness (n). An analytical energy model for air compression of the overall system was created taking into consideration the modeling of individual sub-system components: air compressor, after-cooler, filter, dryer and receiver. The analytical energy model for each subsystem included energy consumption evolution using the theoretical thermodynamic approach. Furthermore, pressure loss models of individual components along with pipe friction loss were included in the system overall efficiency calculation. The efficiency analysis methods and effectiveness approach discussed in this study were used to optimize energy consumption and quantify energy savings. The method was tested through a case study on a plant of a die-casting manufacturing company. The experimental system efficiency was 76.2% vs. 89.3% theoretical efficiency. This showed model uncertainty at ~15%. The effectiveness of reducing the set pressure increases as the difference in pressure increase. The effectiveness of using outside air for compressors intake is close to the compressors work reduction percentage. However, it becomes more effective when the temperature difference increase. This is mainly due to extra heat loss. There is potential room of improvement of the various component using the efficiency and effectiveness methods. These components include compressor, intercooler and dryer. Temperature is a crucial parameter that determines the energy consumption applied by these components. If optimum temperature can be determined, plenty of energy savings will be realized.