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Air compressors not only apply almost in all industries but also providing sufficient and stable air pressure supply. In order to achieve the necessary conditions of production flow, instable air supply will influence product quality. Owing to the arrangement at production line and insufficient pressure, air compressors must keep reserve to cope with the demands of production line when installed.

When the air demand at production line is little, air compressors will be run at partial load control mode. The conventional screw type air compressors run at constant frequency, therefore, if the compressor runs at a partial load for a long time, it may lead to system inefficiency and cause the waste of energy.

● Most of traditional screw air compressors run with constant frequency.
The ways of the control exhaust are： (1) load and unload (2) valve
   
Application of energy-saving frequency inverter
  Compressed Air Energy Input and Useful Energy Output
 
   
  Compressed Air Energy Input and Useful Energy Output
 
 
* Source：Compressed Air - Energy Efficiency Reference Guide & Bureau of Energy
 
Discussion on energy saving of compressor with inverter
 
1.   Add unload control mode: 8%-22% of energy saving benefit.
2.   Capacity adjustment (intake throttle) control mode:
About 30% of energy saving benefit.
3.   Inverter control (constant output pressure) mode:
   
● The control range of output should be 40%-100%.
   
● The power consumption is about 50% for 50%-54% of output.
     
* Source：Bureau of Energy
 
Total cost analysis of compressed air system
 
* Source：Bureau of Energy
 
Energy cost analysis of compressed air system
 
1.   Leak is the No.1 deadly enemy for energy cost of compressed air system.
2.   Statistical data of US Department of Energy:
   

● Leak of compressed air is 30%~50% in general factory.
    ● It is 10%~30% in better managed factory or new factory.
    ● 5%~10% is more acceptable range.
3   Artificial demand is the compressed air demand which is not useful for production due to unnecessary or excess expansion.
    ● Cause: Due to improper selection in planning and poor control.
     
* Source：Bureau of Energy
 
Energy saving Principle of Air Compression System
 
 
Actual Case
 
 
 
Rubber and Plastic Processing Machinery < Air Compresser > Pump
 
   
 
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