CASE25 · Manufacturing · Compressed air
Optimizing compressor dispatch and loading/unloading with ten-second data
A graphite and battery-materials factory uses short-interval power, flow and pressure measurements to evaluate large base-load compressors and smaller demand-following units. The proposal combines essential metering with real-time operating guidance.
01 · CASE ANALYSIS
Operating challenge
Rapidly recurring demand changes caused smaller compressors to switch frequently between loading and unloading. Large machines supplied the base load, making dispatch across different capacities a central operating question.
The system operated reasonably well overall. The aim was to sustain efficient combinations and distinguish equipment deterioration from inefficient system operation.
02 · CASE ANALYSIS
Measurements and performance indicators
Power, discharge pressure, header flow, active-unit count and unloading states were aligned at ten-second intervals. System UPI is power in kW divided by airflow in m³/h, giving kWh/m³.
Eight compressors were included in the proposed scope, including two planned additions. The minimum instrumentation package comprised eight current points, ten pressure points and two flow points.
| Indicator | Average | Observed range |
|---|---|---|
| UPI | 0.100 kWh/m³ | 0.092–0.120 kWh/m³ |
| Airflow | 10,016 m³/h | 1,620–18,076 m³/h |
| Header pressure | 7.3–7.4 kg/cm² | 6.5–8.4 kg/cm² |
| Active compressors | 2 | 1–5 |
| Power | 998 kW | 55–1,874 kW |
| Unloading loss | 0.3% | Up to 15% |
03 · CASE ANALYSIS
Operating recommendations
Use measured efficiency and demand to choose large base-load and smaller regulating units. Review pressure bands and control transitions when frequent unloading is observed.
An average unloading loss of only 0.3% should not obscure short events reaching approximately 15%. Examine the associated demand and control states rather than treating the peak as an annual savings rate.
04 · CASE ANALYSIS
Proposal and economics
Annual electricity was approximately 8,741,345 kWh, with a historical electricity cost near KRW 874 million. The proposal estimated approximately 4%, or KRW 35 million/year plus unquantified additional benefits.
The proposal separated consulting/training, metering/server procurement and software deployment. Six months of consulting and six months of system construction were envisaged.
| Work package | Estimated cost |
|---|---|
| Consulting and training | KRW 30 million |
| Metering and server; direct client procurement | KRW 35 million |
| Software development and installation | KRW 35 million |
| Total | KRW 100 million |
05 · CASE ANALYSIS
Verification and transfer
Establish calibrated flow and pressure measurements before setting the operating baseline. Verify electricity under comparable delivered-air volume, pressure, production demand and operating hours.
Reduced power accompanied by reduced service pressure or airflow is not automatically an efficiency improvement.
APPLY TO YOUR SITE
Connect your operating data to an actionable energy strategy.
Discuss the measurement boundary, data quality, operating constraints and verification approach for your facility.
Discuss your project All English cases