Compressed Air Energy Facts

  • Compressed Air is NOT free - it costs the equivalent of 50p/kWh.
  • Leakage rates of 30% are common throughout industry.
  • At 7 bar and 4.5p/kWh the annual kW use and cost, if the compressors are not switched off for:
Hole Diameter Power Wasted Cost per Year (8000 hrs) CO2 Loss
0.4mm (pin prick) 800kW £36 352kg
1.6mm (pin head) 8000kW £360 3520kg
3.0mm (match head) 28000kW £1260 12320kg
  • A reduction of 4°c in compressor intake temperature increases the efficiency by 1%.
  • Typically a kW of compressed air costs 10x that of the cost of electricity.
  • Over a 10 year period the total cost of a compressor can be split:15% Capital Cost, 10% Maintenance Cost, 75% Energy Cost.
  • 100kW (605cfm) running 24 hours per day, 7 days per week.
  • Energy cost per year @5p/kWh is £40,000.
  • The CCL will have increased this by £3,440 p.a
  • Reducing the pressure by 1 bar will save approximately 4%.
  • A 3bar compressor will generate air 33% cheaper than a comparable 7bar machine.

Energy Saving Techniques

  • Match the compressor size to demand.
  • Generate at the lowest acceptable pressure.
  • Use waste heat from compressors for space or water heating.
  • Check for leaks regularly and repair promptly.
  • Zone the system and isolate pipework when not in use.
  • Remove or shut off permanently unused pipework.
  • Use solenoid valves to isolate machinery which is prone to leakage.
  • Check pressure drops across filters and replace promptly when drops become excessive.
Go to the BCAS official site
 
 

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