CASE16 · Manufacturing · Compressed air
Optimizing automotive compressed air through UPI, staging and demand patterns
Power, airflow, pressure, IGV/BOV behavior and process-level demand are analyzed together. A small UPI improvement represents a meaningful cost opportunity in a large compressed-air system.
01 · CASE ANALYSIS
Operating challenge
Annual compressor electricity was approximately 37.12 million kWh. Separate high- and low-pressure circuits required demand-based staging and pressure review.
IGV control was generally satisfactory, but BOV opening during supply-demand imbalance was associated with higher losses and UPI. Three major production processes accounted for about 73% of air demand.
02 · CASE ANALYSIS
Data and performance diagnosis
The analysis combined system power, normalized airflow, supply/discharge pressure, running/required units, IGV opening, BOV state, load, loss and process-level flow patterns.
Mean UPI was approximately 0.106 kWh/Nm³ against a proposed reference of 0.104. Average load was about 91%. The detailed actual-versus-required table reports about 4.6 operating units against 4.1–4.2 required, within a 2–8-unit operating range.
| Indicator | Value |
|---|---|
| Mean UPI / reference | 0.106 / 0.104 kWh/Nm³ |
| Mean load | 91% |
| Operating / required units | Approximately 4.6 / 4.1–4.2 |
| Operating range | 2–8 units |
| Demand in three main processes | Approximately 73% |
03 · CASE ANALYSIS
Supply and demand measures
Select efficient unit combinations according to airflow demand, review pressure margins against end-use needs and pressure losses, and reduce BOV venting through better supply-demand balancing.
On the demand side, prioritize the main consuming processes and examine peaks, non-production periods and abnormal usage using their flow meters. Existing pressure control was generally sound, so adjustments should be incremental and protect production requirements.
04 · CASE ANALYSIS
Potential and M&V
The source estimates KRW 70,041,685/year if the mean UPI approaches the 0.104 reference. This is an operating-data-based cost potential.
Verify with air production, production conditions, operating hours, pressure and demand reflected in the baseline. BOV loss correlation supports diagnosis but does not alone quantify a verified saving.
| Area | Action | Evidence status |
|---|---|---|
| UPI | Approach 0.104 reference | KRW 70,041,685/year potential |
| Staging | Demand-based efficient combinations | Operating margin approximately 0.4–0.5 units |
| IGV/BOV | Minimize imbalanced venting | Observed loss/UPI relationship |
| Demand side | Peak and non-production use management | Flow-based priority selection |
05 · CASE ANALYSIS
Engineering lesson
At large utility scale, small intensity changes can matter. Supply optimization and demand management should be coordinated, with the measured airflow denominator kept consistent.
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