Absolute Energy SavingUpgrade to cut energy consumption for

reciprocating compressors

Energy balance for a typical (1 to 4 MW) reciprocating compressor operating in refinery.

2% - 7%

friction losses

valve lossesleaks from piston rings and packings

packing friction losses

bypass energy losses

3% - 10%

0,5% - 1%1% - 3%

12% - 50%

indicated compression energy

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by t

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How can I save energy?

You can save energy by keeping your

compressor in good running order, by

using the best available technology

for valves, rings and packings, and by

choosing effective control strategies.

This is easy to say, but how do you

quantify these savings and make sure

any improvements will be cost-effective?

What if you could benchmark your

compressor’s performance against a

large population of similar compressors?

With HOERBIGER you can do just

that. HOERBIGER’s proprietary system

carries information from over 50,000

reciprocating compressors covering

virtually every compressor type and

gas service. Using our specialized

tools as RecipCOM, we can audit your

compressor’s performance and map it

against other similar compressors. The

audit may uncover opportunities for

improving the maintenance or operation

of your equipment.

If you operate reciprocating compressors, the chances are you’re sensitive to energy consumption.

After all, your energy bill directly influences your production costs. The good news is that for

large machines just a small improvement in efficiency - say 3% - means significant savings. As

an independent service partner and technology leader for critical components and systems for

reciprocating compressors HOERBIGER can bring you these savings and more.

Energy: more important than ever

Sources: Charles Bouché, Karl Wintterlin: Kolbenverdichter, Springer Verlag

Where can I save energy?

What savings can I expect?Starting from a detailed compressor energy balance, HOERBIGER experts quantify

the costs and benefits of upgrades to valves, rings, packings and compressor

controls. The result is higher efficiency, energy savings and lower operating costs.

The potential reduction in power consumption multiplied by the number of running

hours per year gives the energy saved per year. Using less energy can save you money

in two ways: through lower electricity bills, and by cutting CO2 emissions that are

charged under emissions trading schemes (ETSs) or carbon taxes.

In short the mechanism works as follows: reduced electricity consumption requires

less output from power plants. Less fuel is consumed, and less CO2 emitted. This is

good news for compressor operators, who can sell the resulting spare CO2 emissions

permits.

Forming the energy balance of a reciprocating compressor gives a comprehensive picture of the losses.

HOERBIGER provides solutions for valves, cylinder rings & packing cases and compressor control

systems to raise the efficiency of the machine. This leads to energy saving and CO2 tax reduction.

power reduction[kW] x

x

x

x

=

=

=

working hours[h]

energy price[€/kWh ]

specific CO2 emission*

[t CO2/kWh]

CO2 certificate price [€/t CO2]

energy saving[kWh]

money saving[€]

*Specific emission: the quantity of CO2 emitted from a power plant for each unit of electricity produced. For example, a CHP

(combined heat and power) plant with a gas turbine emits about 0.45 t CO2/MWh.

The worksheet on the next page looks at the compressor energy balance in more detail

General informationCompressor operating hours per year:

Electricity cost (typically 100 €/MWh)

CO2 specific emission (typically 0,45 t CO2/MWh for a CHP plant)

CO2 cost (~15 €/t for 2010 in the EU)

Compressor Valve: What type of valves are used?

How clean is the compressed gas?

Main packing cases: How many packing cases are installed on the compressor?

How many tangential radial rings pairs are in each packing case?

What is the final discharge pressure?

Control: What kind of control is used?

range of control [0-100%]

average load [0-100 %]

Energy saving formFill in the boxes and send this form to info-hktes@hoerbiger.com to see how much

energy you might save by updating your reciprocating compressor to the latest

performance standards.

h

€/MWh

t CO2/MWh

€/t CO2

clean dirty

bypass

plate valves ring valves profiled plate valves

on/off step control reverse flow clearance pockets

HOERBIGER Compression Technology is a business unit of HOERBIGER Holding AG, Zug / Switzerland. HOERBIGER is active

throughout the world as a leading player in the fields of compression technology, automation technology and drive technology.

In 2011, its 6,826 employees achieved sales of 1.048 billion Euro. The focal points of its business activities include key

components and services for compressors, gas engines and turbomachines, hydraulic systems and piezo technology for vehicles

and machine tools, as well as components and systems for shift and clutch operations in vehicle drive trains of all kinds.

Through innovations in attractive technological niche markets, the HOERBIGER Group sets standards and delivers cutting-edge

solutions for the benefit of its customers.

This product brochure contains product specifications based on research and development on the one hand and on manufacturing on the other. Dependent on place of installation, operating

conditions and specifications, several parameters of the described product may change. Thus, HOERBIGER assumes no liability or warranty for the accuracy and completeness of the

information covered in this brochure.

www.hoerbiger.com

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