Technical Data

Breakdown of Compressed Air Costs over 10 Years

Breakdown of Typical Plant Air Consumption

Compressor Control Comparison Of Full Load BHP Versus % Of Full Load Capacity

% of Compressor Capacity Modulation (Inlet Valve) % FL BHP Variable Displacement (Geometry) % FL BHP On-Line / Off-Line  Variable Speed Drive
1 Gal/CFM 3 Gal/CFM 5 Gal/CFM
% FL BHP % FL BHP % FL BHP % FL BHP
100 100.00 100.00 100.00 100.00 100.00 100.00
95 98.50 96.00 101.51 100.49 99.95 95.20
90 97.00 92.00 100.44 98.36 97.28 90.40
85 95.50 88.20 99.28 96.11 94.51 85.60
80 94.00 84.70 98.02 93.71 91.61 80.80
75 92.50 81.50 96.64 91.17 88.59 76.00
70 91.00 78.30 95.12 88.46 85.43 71.20
65 89.50 75.40 93.45 85.57 82.10 66.40
60 88.00 73.00 91.58 82.49 78.63 61.60
55 86.50 70.80 89.49 79.19 75.02 56.80
50 85.00 69.00 87.13 75.67 71.25 52.00
45 83.50 64.60 84.44 71.89 67.34 47.20
40 82.00 60.20 81.35 67.80 63.28 42.40
35 80.50 55.80 77.76 63.41 59.06 37.60
30 79.00 51.40 73.53 58.76 54.69 32.80
25 77.50 47.00 68.51 53.84 50.15 28.00
20 76.00 42.60 62.48 48.65 45.46 23.20
15 74.50 38.20 55.19 43.17 40.60 18.40
10 73.00 33.80 46.26 37.41 35.57 13.60
5 71.50 29.40 36.19 31.36 30.37 8.80
0 70.00 25.00 27.33 26.30 26.09 4.00

 

Sample Power Cost Numbers

Single shift operation / 10 hours per day / 5 days per week / $0.05 per kw

HP Full load power cost 70% load 70% load 70% load 50% load 50% load 50% load
    modulation On-Line / Off-Line Variable Displacement modulation On-Line / Off-Line Variable Displacement
50 5,759.00 5,241.00 5,478.00 N/A 4,895.00 5,018.00 N/A
75 8,013.00 7,291.83 7,628.38 6,274.18 6,811.05 6,981.73 5,528.97
100 10,776.00 9,806.16 10,258.75 8,437.61 9,159.60 9,389.13 7,435.44
125 13,619.00 12,393.29 12,965.29 10,663.68 11,576.15 11,866.23 9,397.11
150 17,242.00 15,690.22 16,414.38 13,500.49 14,655.70 15,022.95 11,896.98
200 21,758.00 19,799.78 20,713.62 17,036.51 18,494.30 18,957.75 15,013.02
250 27,390.00 24,924.90 26,075.28 21,446.37 23,281.50 23,864.91 18,899.10
300 33,249.00 30,256.59 31,653.05 26,033.97 28,261.65 28,969.85 22,941.81
Variable speed units
  70% Power Cost 50% Power Cost          
160HP 11,754.60 8,139.30          
100HP 7,362.00 5,265.00          
67HP 4,978.00 3,528.00          

 

Sample power cost numbers

Three shift operation / 24 hours per day / 7 days per week / $0.05 per kw

HP Full load power cost 70% load 70% load 70% load 50% load 50% load 50% load
    modulation On-Line / Off-Line Variable Displacement modulation On-Line / Off-Line Variable Displacement
50 19,404.00 17,658.00 18,457.00 N/A 16,493.00 16,907.00 N/A
75 26,997.00 24,567.27 25,701.14 21,138.65 22,947.45 23,522.49 18,627.93
100 36,306.00 33,038.46 34,563.31 28,427.60 30,860.10 31,633.42 25,051.14
125 47,740.00 43,443.40 45,448.48 37,380.42 40,579.00 41,595.86 32,940.60
150 58,093.00 52,864.63 55,304.54 45,486.82 49,379.05 50,616.43 40,084.17
200 73,307.00 66,709.37 69,788.26 57,399.38 62,310.95 63,872.39 50,581.83
250 92,283.00 83,977.53 87,853.42 72,257.59 78,440.55 80,406.18 63,675.27
300 112,025.00 101,942.75 106,647.80 87,715.58 95,221.25 97,607.38 77,297.25
Variable speed units
  70% Power Cost 50% Power Cost          
160HP 39,495.46 27,348.05          
100HP 24,886.00 17,740.00          
67HP 16,771.00 11,887.00          

 

Cost of Air Leaks Single shift operation / 10 hours per day / 5 days per week / $0.05 per kw
1/4" air leak at 100PSI consumes approximately 104CFM - which comes to a yearly power cost of $2,235.00
1/2" air leak at 100PSI consumes approximately 415CFM - which comes to a yearly power cost of $8,483.00

 

Cost of Air Leaks Three shift operation / 24 hours per day / 7 days per week / $0.05 per kw
1/4" air leak at 100PSI consumes approximately 104CFM - which comes to a yearly power cost of $7,530.00
1/2" air leak at 100PSI consumes approximately 415CFM - which comes to a yearly power cost of $28,580.00