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Technical Paper

Efficiency Improvements for Compressed Air Systems

2012-04-16
2012-01-0327
Compressed air systems are employed in virtually all manufacturing plants, including automotive industries, and compressed air systems can account for five to twenty percent of plant energy consumption. Therefore, exploring opportunities to decrease the energy consumption of this equipment can result in significant energy and cost savings, resulting in more energy efficient automotive plants. In this paper, a case study for a 360,000 square-foot automotive interiors plant operated by Johnson Controls andlocated in Alabama, United States is considered. The plant uses two 150 horsepower rotary screw compressors which deliver an average of 800 cubic feet per minute with an energy usage of 1,414,000 kWh per year. A compressed air system analysis was performed at this plant using the Department of Energy (DOE) software tool AIRMaster. Energy usage was determined by measuring the current draw from the air compressors using data loggers over a period of two weeks.
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