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Determine the Cost of Compressed Air for Your Plant

Most industrial facilities need some form of compressed air, whether for running a simple air tool or for more complicated tasks such as the operation of pneumatic controls. A recent survey by the U.S. Department of Energy showed that for a typical industrial facility, approximately 10% of the electricity consumed is for generating compressed air. For some facilities, compressed air generation may account for 30% or more of the electricity consumed. Compressed air is an on-site generated utility. Very often, the cost of generation is not known; however, some companies use a value of 18-30 cents per 1,000 cubic feet of air. Compressed air is one of the most expensive sources of energy in a plant. The over-all efficiency of a typical compressed air system can be as low as 10%-15%. For example, to operate a 1 - horsepower (hp) air motor at 100 pounds per square inch gauge(psig), approximately 7-8 hp of electrical power is supplied to the air compressor.

Typical Lifetime Compressed Air Costs in Perspective—Costs Over 10 Years

Assumptions in this example include a 75-hp compressor operated two shifts a day, 5 days a week at an aggregate electric rate of $0.05/kWh over 10 years of equipment life.

Air consumption cost graph

Air consumption cost graph

Compressed air vs. other energy sources

Although compressed air is a necessary part of most plant operations, it is not the most efficient source of energy in a plant (see Fig. 1). To operate a 1 hp air motor requires 7-8 horsepower of electrical power into the compressor. At higher-than-typical pressures, even more power is needed. 30 scfm @ 90 psig is required by the 1 hp air motor. 6-7 bhp at the compressor shaft is required for 30 scfm.7-8 hp electrical power input to the compressor is required for 6-7 bhp at the shaft of the compression element. The overall efficiency of a typical compressed air system can be as low as 10-15%. Annual energy costs for a 1 hp air motor vs. a 1 hp electric motor in a 5-day-per-week, 2-shift operation, at $0.05/kWh is $1164 (compressed air) vs. $194 (electric). This means the compressed-air-powered motor can cost more for the same power output—significantly more if plant pressures are higher than the estimated level of 90 psi.

Air vs Electric comparison cost graph

Air vs Electric comparison cost graph

Reducing the Productive Cost of Your Plant

Electromechanical Servo Presses are now a good economic alternative in confront classic Hydraulics or Pneumatic Presses. In all heavy applications where are required elements like flexibility, exact positioning, extremely high reproducibility and accurately defined press-fitting forces, Electromechanical Servo Presses give a better answer concern this items. Our electromechanical servo presses, further this paradigms doing a step ahead in fields such as energy cost saving and low cost maintenance, and for this reason we could say our presses help industries to improve the foot print, thing very important nowadays, how you can see on U.S. Office of Energy Efficiency and Renewable Energy (EERE) . Further the cost saving, servo press own characteristics of accuracy, flexibility, precision and repeatability impossible to reach with traditional hydraulic or pneumatic presses.

servo press

The use of Servo Presses cut of 6 fold the energy annual cost

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Air Cost

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