Improving Compressed Air Energy Efficiency in Automotive Plants

Automotive stamping and assembly plants are typically large users of compressed air with annual compressed air electricity bills over $500,000 per year. This paper describes typical compressed air systems in automotive stamping and assembly plants, and compares these systems to best practices. The paper then presents a series of case studies, organized using the inside-out approach, that identify significant energy savings in automotive plants. Case studies include ways to reduce end use compressed air by replacing pneumatic motors with electric motors and replacing pneumatic suction cups with magnets, reduce distribution losses by replacing braided with rubber hoses, reduce drying losses by employing demand-based desiccant regeneration, and control losses by increasing throttling capability and operating centrifugal air compressors in auto-dual control mode. PAPER OUTLINE This paper presents a series of case studies that identified significant energy savings in automotive plants. The case studies are presented using the inside-out approach of first minimizing end use demand, then minimizing distribution losses, and finally making improvements to primary energy conversion equipment, the air compressor plant (Kissock, XXXX). Case studies include ways to reduce end use compressed air by replacing air-powered tools with electric tools and replacing pneumatic suction cups with magnets, reduce distribution losses by replacing braided with rubber hoses, reduce drying losses by employing demand-based desiccant regeneration, and reduce control losses by increase throttling range and operating centrifugal air compressors in auto-dual control mode.