Alexander Pavlov

IETC, New Orleans, 20-21/05/10

Energy Efficiency in Compressed Air Systems

2

Atlas Copco in a Snapshot

A world-leading provider of industrial productivity solutions.

Products and services range from compressed air and gas equipment, generators, construction and mining equipment, industrial tools and assembly systems, to related aftermarket and rental.

In close cooperation with customers and business partners, Atlas Copco delivers sustainable solutions for increased productivity through innovative products and services.

Headquartered in Sweden, the Group’s global reach spans more than170 markets.

In 2009 Atlas Copco had 30 000 employees and annual revenues of approximately BSEK 64 (BEUR 6.0).

3

The Atlas Copco Organization

Executive Group Management and Corporate Functions

Oil-free Air

Industrial Air

Portable Air

Specialty Rental

Gas and Process

Compressor Technique Service

Airtec

CompressorTechnique

Construction and Mining Technique

IndustrialTechnique

Underground RockExcavation

Surface DrillingEquipment

Drilling Solutions

Secoroc

Construction Tools

Road Construction Equipment

Geotechnical Drillingand Exploration

Rocktec

Atlas Copco Tools and Assembly SystemsMotor Vehicle Industry

Atlas Copco Toolsand Assembly Systems General Industry

Chicago Pneumatic

Tooltec

Customer Centers and Service Providers

President and CEO

Board of Directors

4

Worldwide Presence

Production sites

5

Value of Energy in Compressed Air Systems

70% to 80% of life cycle costs is energy

In EU compressed air accounts for 10% of the energy consumed by industry

1 bar lower in pressure, reduces energy by 7%

Typically, after 5 years leakages can take 20% of the total air consumption

Some useful facts and figures

Investment 12%

Installation 3%

Maintenance 15%

Energy consumption 70%

Energy Savings

6

CO2 emissions – the big picture

Design of product

Logistics Energy use

Re-use

Design of product

Less electricity consumption

Atlas Copco focus

(95% +)

7

Why Atlas CopcoSaving energy is our way of life

A century of innovation in energy saving features

Over 400 patents

8

EU electricity consumption in compressed air

Real consumption in CAS TWh Share of electricity

In EU the compressed air accounts for 10% of the energy consumed by industry, 80 TWh/year

Source: Compressed air systems in the European Union, 2001, study by Fraunhofer Institute, ADEME, ECE, University of L’Aquila

9

Potential contribution to energy savings

System installation or renewal % applicability(1) % gains(2) Potential contribution(3)

Improvement of drives (high efficiency motors, HEM) 25 % 2 % 0.5 %

Improvement of drives (adjustable speed drives, ASD) 25 % 15 % 3.8 %

Upgrading of compressor 30 % 7 % 2.1 %

Use of sophisticated control systems 20 % 12 % 2.4 %

Recovering waste heat for use in other functions 20 % 20 % 4.0 %

Improving cooling, drying and filtering 10 % 5 % 0.5 %

Overall system design, including multi-pressure systems 50 % 9 % 4.5 %

Reducing frictional pressure losses 50 % 3 % 1.5 %

Optimising certain end use devices 5 % 40 % 2.0 %

System operation and maintenance

Reducing air leaks 80 % 20 % 16.0 %

More frequent filter replacement 40 % 2 % 0.8 %

TOTAL 32.9 %

Table legend: (1) % of CAS where this measure is applicable and cost effective(2) % reduction in annual energy consumption(3) Potential contribution = applicability * reduction

Source: Compressed air systems in the European Union, 2001, study by Fraunhofer Institute, ADEME, ECE, University of L’Aquila

32.9 % = 30.5 TWh/yr = 0.7 million tonnes of CO²/yr

10

Superior solutions

Total energysaving concept

From products to solutionsThe unique approach

Customer needs

coretechnology

drivetechnology

energy saving accessories

energy recovery

demandassessment

optimizationof the room

11

The Energy Circle

Superior solutionsCustomer needs

coretechnology

drivetechnology

energy saving accessories

energy recovery

demandassessment

optimizationof the room

12

Demand assessment

System audit:– Flow measurement

– Pressure measurement

– Power measurement

Report:– Simulation of optimal compressor installation

– Simulation of central control system

– Potential energy savings

Overall system design

13

Leak detection

Ultrasound leak detection

Report– Location

– Leak flow

– Equivalent energy loss

14

System assessmentAirScan - Tools

Hot tapping

Temperature

Leak detection

Flow

Dewpoint measurement

Power/logging device

VIP sens

Measurement box

Flow measurement output

15

The Energy Circle

Superior solutionsCustomer needs

coretechnology

drivetechnology

energy saving accessories

energy recovery

demandassessment

optimizationof the room

16

Oil-free screw compressors55-900 kW

Oil-injected screw compressors5-500 kW

Turbo compressors500-2500 kW

Matching air treatment equipmentDryers,filters,drains,separators,etc

ES – energy saving central controllersOptimization, monitoring, control

Oil-free scroll compressors1-15 kW

Oil-free tooth compressors15-45 kW

Best compression and treatment technologies under one roof

Products

17

Atlas Copco has all the technologies availableS

pec

ific

en

erg

y J/

l (H

p/c

fm)

centrifugalscrewtooth

Power (flow)

scroll

Appropriate selection can save a lot of energy

18 kW 55 kW 750 kW

Energy Savings

18

Before 19902008

Sp

ec

ific

En

erg

y (

J/l

, H

p/c

fm)

1 10 (21.2) 100 (212) 1000 (2,120)

FAD l/s (cfm)

1995 - 20032000 - 2006

System design : innovations in screw elements

3-5%

3%

11kW 22kW 30kW 55kW 90kW 132kW 200kW 300kW

5-6%

19

The Energy Circle

Superior solutionsCustomer needs

coretechnology

drivetechnology

energy saving accessories

energy recovery

demandassessment

optimizationof the room

20

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Sunday

l/s

hour

50

100

150

200

250

Typical air demand pattern

Measurement and simulation tools are available to calculate precise energy savings in a real environment

Energy Savings

Average use 50%

21

time

Theory

Loaded pressure

Unloaded system pressure

Energy savings with VSD

T

T- time for complete system venting

Actual

Excess energy

Power consumption during transition from load to no load with traditional regulation

seconds

kW

0

10

20

30

40

50

0

20

40

60

80

10

0

12

0

14

0

16

0

18

0

20

0

22

0

24

0

26

0

Power consumption GA45 L-NL at 50%

Energy savings with VSD

~80%

Power consumption during transition from load to no load with traditional regulation vs. VSD

VSD

23

VSD technology can save up to 35% of energy

centrifugalscrewtooth

Flow m3 / min

scroll

18 Kw 55 Kw 750 Kw

$/M3

Sp

ecif

ic e

ner

gy

J/L

or

$/M

3Energy cost per m3 of air at 7 bar(e) (100 psig)

VSD – Variable speed drives

24

0 250 500 750 1000 kW

Company A

Company B

Company E

Others : mainly promoting free-standing

Company C

Company D

Atlas Copco

Widest integrated VSD range (from 7.5 to 900 KW)

Our commitment to VSD technology

25

The Energy Circle

Superior solutionsCustomer needs

coretechnology

drivetechnology

energy saving accessories

energy recovery

demandassessment

optimizationof the room

26

MD and XD dryers – energy-less air drying

Heat of compression is used for drying

No external energy or purge is required

Very low pressure drops

Energy savings between 5 and 20% are possible !

Efficiency – Air quality

27

Dryer energy consumption (-20oC, -4°F PDP)

Type of dryer

% o

f co

mp

ress

or

po

we

r

7.70%

19.53%

2.30%

0.02%0%

5%

10%

15%

20%

25%

BD heat reactiveted CD purge reactivated XD 0 purge HOC MD HOC

28

The Energy Circle

Superior solutionsCustomer needs

coretechnology

drivetechnology

energy saving accessories

energy recovery

demandassessment

optimizationof the room

29

PRESSURE BAND CASCADE

com-pressor

1

com-pressor

2

com-pressor

3

com-pressor

4

Ne

t p

res

su

re

Time

LOCAL CONTROLCENTRAL CONTROL

Average pressure

Required minimum pressure

HIGH COSTS LOW COSTS

Energy savings through optimization

ES controls the net pressure– Net pressure is guaranteed while compressors run at lowest required pressure

Lower pressure by 1 bar reduces energy by 7%

30

Automatic selection of “Best Size” compressor

Net pressure drops fast

Net pressure drops slowly

Pre

ssu

re

Time

Pre

ssu

re

Time

Big compressor

Small compressor

31

Efficient?

Optimization of VSD compressors

VSD 2: ~ 70%

Local control

Flo

w

Time

VSD 2: 50%

VSD 2: ~50%

ES optimization

Flo

w

Time

VSD 1: 30%

SE

R (

J/l)

Flow (l/s)

VSD 1 VSD 2

SE

R (

J/l)

Flow (l/s)

VSD 1 VSD 2

32

Optimization of Turbo’s and VSD

Efficient?

Local control

SE

R (

J/l)

Turbo 2

Turbo 1

SE

R (

J/l)

Flow (l/s)

VSD

SE

R (

J/l)

Flow (l/s)VSD

Blow-off SE

R (

J/l)

Turbo 1Blow-off

Turbo 2

Flo

w

Time

Turbo 2: 50%(blow-off ~20%)

Turbo 1: 100%(blow-off 0%)

VSD 2: 90%

ES optimization

Flo

w

Time

Turbo 2: 80%(blow-off 0%)

Turbo 1: 100%(blow-off 0%)

VSD 2: 50%

….. …..

33

Carbon ZeroThe unique approach

coretechnology

drivetechnology

efficient air treatment

optimizationof the room

demandassessment

‘Carbon Zero’

“net zero energy”

The new milestone

Recovery

34

Measured parameters TÜV test

35

Type test of ZR 55-750 range with built-in energy recovery systemsType test of ZR 55-750 range with built-in energy recovery systems

Comparison of the electrical energy consumption with heat energy recoveredComparison of the electrical energy consumption with heat energy recovered

Certified results “100% of the electrical energy

consumed could be recovered” “ net power (energy) consumption of

the ZR compressor with built-in energy recovery at specific design conditions is zero”

Certified results “100% of the electrical energy

consumed could be recovered” “ net power (energy) consumption of

the ZR compressor with built-in energy recovery at specific design conditions is zero”

36

Introducing Carbon Zero

Electrical energy input converted

to heat

10% losses in radiation, etc.

Direct energy recovery 90%

Energy in atmospheric air

(latent heat)

Atmospheric energy 12%

102

Result – Net Zero energy consumption

Released due to condensation in coolers

100%

15%

37

Carbon Zero principal build-upZR Energy recovery

ZR Energy recovery

Oil cooler

HP element

LP element

Aftercooler

Intercooler

Thermostatic valve

ER control unitWater circuit

42%

37%

9%

12%

Recovered energy at 10 bar(e) (145 psig)

20-40°C (68-104°F)70-90°C (158-194°F)

38

Components of the energy recovery systems

H H

H

HT

T

TI

PI

H H

H H

Control unit scope is within the dashed line. Outside is customer’s scope.

H

Heat consumer

ZR

Secondary cooling

water system

39

What makes ZR compressor unique

Compared to oil-injected screws– ZR compressors have much higher temperatures due to which they can recover 100% of

the electrical energy as heat, under design conditions. Watercooled OIS can recover +/- 70%

Compared to turbos– Lower temperatures in turbos restrict energy recovery severely

– Interstage energy recovery can create instability

– At reasonable temperatures energy recovery is 30-35%

Compared to other oil-free screws– Others are not recovering energy from oil coolers and jackets, thus losing 20-25%. So

energy recovery with competitors OFS could be at best 80%

40

Applications

Space heating

Showers

Boiler feed

41

Some high level steam applications

42

Example of savings with Carbon Zero

Consider a ZR132 kW compressor and an energy recovery of 135 kW

Heat equivalent per second = 135 kJ/s

When using heating oil (HO)

Calorific value = 41,200 kJ/l

Boiler efficiency = 70% without recovery and 90% with recovery

Heat generated per hour = 135 kJ/s x 3600

Fuel saved = 135 x 3600 / (41,200 x 0.9) = 13 l/h = 3.4 gal/h

Cost of fuel = 0.5€/l x 13 l/h = 6.50 €/h = 8 $/h

Yearly savings = 6.5€ x 8000 h/y = 52,000 € per year = $ 64,000 per year* Calculation based on full load running for 8000 hours – full potential

43

Carbon Zero ZR range

270 m³/h 7,470 m³/h

4 bar(e) 58 psig

10.4 bar(e) 151 psig

ZR 55 – ZR 750

ZR 75 VSD – ZR 700 VSD

159 cfm 4,387 cfm

44

Conclusions: Energy Efficiency in CAS

Reducing air leaks– Ultrasonic leak detection

Overall system design– System audits and simulation

– Optimal compression technologies

– Control and ancillary systems

Use of adjustable speed drives (ASD)– Variable Speed Drives

Recovery of waste heat– Carbon Zero compressors recover up to 100%

Atlas Copco approach

45

Committed tosustainable productivity.

46