Kaeser Compressors, Inc. Compressed Air Efficiency Capturing and Sustaining Energy Savings Wayne Perry Technical Director Kaeser Compressors, Inc.

US Department of Energy Estimates Half of all Compressed Air is Wasted © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Percent of Electricity Consumed by Compressed Air Systems © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

If Compressed Air Systems Were Optimized © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Motor-Driven Systems are Initially Designed With The assumption that “more” is better Little or no thought given to system efficiency No plan for increases or decreases in system demand A “lowest first cost” goal Changes to existing systems face the same issues © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Proper Application of Variable Speed Compressors Single unit Trim compressor Indoors Varying demand If demand is constant, multiple fixed speed compressors can be more efficient. Multiple compressor system with a master controller Where demand fluctuates between minimum and maximum output of the VSD Free from dust and debris © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Fixed Speed Compressor Operation Operate between a defined pressure band Typically idle for specific times between loads prior to shutting down and turning off Typically base load compressors within a system Recommend compressors with varying idle times © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Fixed Speed Compressor Operation Used in base load machines to avoid frequent motor starts © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Building a Compressed Air Station Start with Demand Profile to find optimum combination of compressors System Demand Flow Pattern © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Building a Compressed Air Station Sample Compressor Operation Multiple smaller units versus one larger unit: High system efficiency over entire range Lower overall capital cost to achieve system redundancy Reduced lifetime costs © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Building a Compressed Air Station Sample Compressor Operation © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Benefits of a Master Controller Decouple compressors from demand Optimize the efficiencies of all compressors Maintain the lowest possible operating pressure for further energy reduction © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Benefits of a Master Controller © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Operating Pressure with a Master Controller Properly applied master controllers: Avoid cascading pressure bands Reduce operating pressure to the lowest point possible Anticipate demand events rather than react using timers © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Operating Pressure with a Master Controller © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Good Master Controller Can Provide Up to one year’s worth of recorded data including: Flow Pressure Load/Idle Cycles Graphed Power Cost Load/Idle Power Specific Power Tabular Power Costs © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Benefits of System Optimization Reduced energy consumption Reduced maintenance expense Reduced capital expense Improved reliability of system components Improved product quality Improved productivity © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

System Optimization Case Study   Before System Optimization After System Optimization Savings Plant Avg. kWh/month Avg. cfm/month % Total kWh Tons CO2 A 613,193 141,609,600 339,538 116,676,920 44.63 1,641,930 992 B 617,043 109,663,996 220,817 75,564,957 64.21 2,849,798 1,722 C 526,136 156,964,617 406,410 147,999,355 22.76 2,633,968 1,591 D 1,152,752 309,492,655 777,639 283,542,295 32.54 9,002,721 6,439 E 796,907 218,421,548 570,640 210,462,035 28.39 3,167,736 1,914 Compressed air specific power reduced from: 24.82 kW/100 cfm to 17.00 kW/100 cfm © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Compressed Air as a Utility Case study used a combination of optimization and outsourcing Kaeser’s Sigma Air Utility is the leading provider of outsourced compressed air © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Compressed Air as a Utility: How It Works Company no longer purchases, maintains, or operates any compressors: Energy management is assured NO capital required NO maintenance expenses 100% back-up of all critical components © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Compressed Air as a Utility: How It Works Kaeser can install a Sigma Air Utility in new or existing compressor rooms. © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Compressed Air as a Utility: How It Works If production space is at a premium, the Sigma Air Utility can also be “containerized”. © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com

Visit our booth for more information © 2015 Kaeser Compressors, Inc., USA / V1.1 / www.kaeser.com