COMPRESSED AIR SYSTEMS SAVINGS OPPORTUNITIES AND INCENTIVES

Outline

• Various Savings Opportunities in Compressed Air Systems

• AEP Ohio Compressed Air Incentives Portfolio

• Opportunity Details and Incentives

• Analysis Tools and Resources

Energy Efficiency Opportunities in Compressed Air Systems

• Replace constant speed air compressor with VFD air compressor

• Retrofit VFD on a constant speed compressor • Reducing delivery pressure (2 Psig air reduction = 1%

reduction in compressor power) • Install intelligent controllers to control a group of air

compressors • Replace compressed air-operated knifes and bars with

low-powered, energy efficient blowers • Replace non-cyclic air dryer with thermal mass dryer

Energy Efficiency Opportunities in Compressed Air Systems

• Install No-Loss/Zero-Loss Automatic Drain Valves

• Add Compressor Storage on Load/No Load Systems

• Install Low Pressure Drop Filters

• Install Compressed Air Engineered Nozzles

• Replace Compressed Air Application with Blowers

• Replace Air Motors with Blowers

AEP Ohio Business Incentives Program

• Compressed Air Incentives Portfolio – Prescriptive Measures and Incentives

– Custom Measures and Incentives

Prescriptive Measures and Incentives

• Replace constant speed air compressor with VFD air compressor

• Retrofit VFD on a constant speed compressor • Install No-Loss/Zero-Loss Automatic Drain Valves • Add Compressor Storage on Load/No Load

Systems • Install Low Pressure Drop Filters • Install Compressed Air Engineered Nozzles • Install Refrigerated Cycling Thermal Mass Air

Dryer

Prescriptive Measures and Incentives

Prescriptive Measures and Incentives

Prescriptive Measures and Incentives

Custom Measures and Incentives

• VFD Air Compressor >100 hp

Custom Measures and Incentives

• hp: 200 hp, FL kW:160 kW • Existing control: Inlet-mod • Operating hours: 4000 hrs/yr • Compressor load: 70% • Proposed System: VFD

controlled 200 hp Compressor • Existing power: 160*0.90=

144.3 kW • Existing Energy consumption:

577,548 kWh/yr • Proposed power: 160*0.65=

104 kW • Proposed Energy

consumption: 416,000 kWh/yr

• Energy savings: 161, 548 kWh/yr

• Energy Incentive: $161,548*0.08 = $12,923.84

• Peak demand savings = 25 kW • Demand Incentive=

25.00*$100.00= $2,500.00 • Total Calculated Incentive =

$12,923.84+$2,500=$15,423.8 • Project cost: $80,000.00 • Final reserved incentive =

$15,423.80 as 50% of project cost is higher than the calculated incentive

Install intelligent controllers to control a group of air compressors

• 3, 75 hp compressors working independently consuming 135 kWh/ hr and outputting 750 CFM = 0.18 kW/CFM

• With intelligent controller the compressed air system is consuming 120 kWh/hr and outputting the same load of 750 CFM = 0.16 kW/CFM

• Efficiency Savings: 0.02 kW/CFM = 0.02x 750 = 15 kW

• Energy savings with 4000 hrs a year = 60,000 kWh/yr

• Incentive: $4,800.00

• Project cost: $5,000.00

• Final incentive will be $2,500.00 as 50% of project cost is lower than the calculated incentive

Replace Non-Cyclic Dryer with Cyclic Refrigerated Dryer

• 800 CFM Non-Cyclic Dryer replaced with 800 CFM Cyclic Refrigerated Dryer

• 800 CFM Non-Cyclic Dryer is rated at 6.5 kW and operates 4,000 hrs/yr with a total energy consumption of 26,000 kWh/yr

• 800 CFM Cyclic Dryer is rated at 6.7 kW operates 2,500 hrs/yr with a total energy consumption of 16,750 kWh/yr

• Energy savings: 9,250 kWh/yr

• Calculated incentive: 9,250*0.08= $740.00

• Project cost: 4,000.00

• Final reserved incentive: $740.00 as 50% of project cost is higher than the calculated incentive

Replace Compressed Air Application with Blowers

• Typically used in industrial application such as air knifes, air bars etc…

• 30 CFM air knife application takes 5.4 kW compressed air power (0.18 kW/CFM)

• 30 CFM air can be generated with a blower that is <2 hp (1.85 kW)

• Demand savings of 5.4-1.85= 3.55 kW

• Energy savings of 14,200 kWh/yr with 4000 hrs/yr operating hours

• Calculated incentive: 14,200*0.08= $1,136.00

• Project cost: 1,000.00 • Final incentive will be $500.00 as

50% of project cost is lower than the calculated incentive

Custom Incentives

Custom Worksheet

Analysis Tools and Resources

• Analysis Tools – Air Master+ – Spreadsheet Analysis – Hybrid Approach

• Resources – Improving Compressed Air System Performance, A

source book for industry from US DOE – Compressed air and gas handbook – Compressed Air Systems, H. P. Van Ormer

Questions?

• How can we help?

• Contact us at:

AEP Ohio Business Incentives Program

Phone: (877) 607-0739

Fax: (877) 607-0740

Email: aepohioincentives@dnvkema.com

Website: AEPOhio.com/Incentives

Thank you!