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Southwest Energy Efficiency Project Southwest Energy Efficiency Project

Compressed Air Systems

Compressed air accounts for about 5% of total electricity consumption in industry. Most plants use compressed air for at least some functions; for many, compressor energy is a substantial portion of the electric bill. Many compressor systems are poorly laid out, have leaking fixtures, and motor/compressor systems are frequently mismatched to loads. Suggestions for curbing energy waste in air compressor systems include the following:

Use properly-sized, energy-efficient compressors driven by energy-efficient motors and associated storage tanks that are matched to loads. Ensure that systems can operate efficiently at part loads. Use electronic controls on individual compressors to optimize pressure and output. Consider installing a smaller, high pressure compressor to meet a specific need in order to allow the main compressor to operate at a lower pressure. Meter energy, flow, and other parameters to assess performance. Maintain the system to minimize air leakage.

Technical resources and a compressed air assessment tool (Airmaster+) are available through the DOE’s Industrial Technologies Program.