Energy Saving Potential in Existing Volumetric Rotary Compressors

The issues of energy and Carbon saving in energy intensive sectors, along with that of energy generation from renewable sources, have been recently receiving a growing awareness, as they are perceived as the most effective ways to deal with global sustainability commitments. The Compressed Air Sector (CAS) accounts for a 10% worldwide electricity consumption, and thus is being re-thought as an area offering great opportunities for improvement. Considering that the compression is responsible for a 10-15% consumption, it is vital to pay attention to machines performances. An overview of present compressor technology is given and saving directions for Screw and Sliding Vanes machines are analysed: interesting source of information was the Compressed Air and Gas Institute (CAGI), whose data have been processed, in order to obtain consistency with fixed reference pressures, and organized as a function of main operating parameters. The overall efficiency has been split and all different sub-terms (adiabatic, volumetric, mechanical, electrical, organic) considered separately. This has allowed a term-by-term evaluation of the margin for improvement. The heat recovery from the oil into mechanical energy via an Organic Rankine Cycle (ORC), together with the thermodynamic improvement during compression phase opens the way to a step change concerning the specific energy consumption.The Authors acknowledge Ing. Enea Mattei S.p.A. and particularly its CEO, Dr. Giulio Contaldi, for continuous research funding and support. The work has been done also under the FP7 Project ”Complete Vehicle Energy-Saving CONVENIENT” funded by the European Commission