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10 Ways to Improve Compressor Efficiency

 

1. Install a Variable Speed Drive (VSD) Compressor

If your air demand fluctuates significantly, a VSD compressor can offer massive savings. Unlike fixed-speed compressors that run at full power and cycle on and off (leading to inefficient unloaded running), a VSD unit matches its motor speed to the required air demand, ensuring it only consumes the energy necessary to produce the required volume of air at the set pressure. This is a highly effective way to reduce the energy-cost component of your total life cycle cost (LCC).

2. Check and Maintain Air Quality Equipment

Dryers and filters are essential for protecting your tools and product quality, but they consume energy and can become inefficient if not maintained.

• Filters: Clogged or dirty filters increase pressure drop across the system, forcing the compressor to work harder (at a higher pressure) to deliver the same required pressure at the point of use. Regularly changing or cleaning filters according to manufacturer recommendations minimizes pressure drop.

• Dryers: Incorrectly specified or malfunctioning air dryers (especially refrigerated or desiccant types) can consume excessive energy. For example, some desiccant dryers continuously purge air even when not needed. Consider zero-loss drain options and ensure the dryer is properly sized and maintained.

3. Optimize the Cooling System and Air Intake

The cooler the air entering the compressor, the more efficient the compression process.

• Intake Air: Ensure the compressor is drawing in cool, clean air from outside the building, if possible. For every 3C (5.4F) drop in intake air temperature, the compressor's energy consumption can decrease by approximately 1%. Avoid placing the compressor near heat sources.

• Cooling System: The compressor's own cooling system (fans, air coolers, water coolers) must be kept clean and free of dust or scale to effectively dissipate heat. Poor cooling can lead to high operating temperatures and reduced efficiency.

4. Implement a Preventive Maintenance Schedule

Preventive maintenance is crucial for sustaining peak efficiency. Ignoring maintenance will inevitably lead to decreased performance and eventual component failure. A comprehensive schedule should include:

• Oil changes and checks: Using the correct oil and changing it on schedule ensures optimal lubrication and cooling.

• Separator and filter element replacement: Prevents contamination and pressure drop.

• Coupling and motor alignment checks: Reduces friction and energy waste.

• Regular professional auditing: Having your system audited by an expert can identify hidden leaks, control issues, or efficiency opportunities you may have missed.

5. Install a System Controller

For facilities with multiple compressors, a central or master controller is essential. While point 6 in our guide mentioned cascading pressure bands, a dedicated controller goes further by:

• Optimizing load sharing across all units.

• Selecting the most efficient combination of compressors to meet the current demand.

• Minimizing unloaded running and trim compressor cycles.

• Equalizing running hours to simplify maintenance and prolong machine life. This single investment ensures your entire system operates as a unified, highly efficient network.
   

If the above tips ignites your need for saving energy you can download our 10 point guide to improving your compressed air system