What is the IND090 datasheet?
The IND090 datasheet - Replacing a compressed air compressor with a high-efficiency compressor - covers the replacement of obsolete or low-efficiency industrial compressed air compressors with next-generation compressors offering better specific performance (kW/m3/min).
Compressed air is one of the largest electricity consumers in industry (it accounts for between 10% and 30% of the electricity consumption of a typical industrial plant). Replacing old compressors with efficient models generates significant savings and is one of the most accessible datasheets in the catalogue.
Scope of application
- Industrial facility with a compressed air system
- Replacement of an existing compressor with a higher-efficiency compressor
- The new compressor must have a lower specific power than the old one (fewer kW per m3/min produced)
- Applicable to screw, piston or scroll compressors
Calculation formula
Saving (kWh/year) = (P_before - P_after) x H x FC
Where:
- P_before: rated power of the old compressor (kW)
- P_after: rated power of the new compressor (kW), adjusted if the production capacity differs
- H: annual operating hours
- FC: average load factor (proportion of time the compressor runs at full load)
Worked example
A manufacturing plant with a 90 kW screw compressor that is 15 years old:
- Compressor before: 90 kW, specific power 7.5 kW/(m3/min)
- Compressor after: 75 kW, specific power 5.8 kW/(m3/min) with integrated variable speed drive
- Operating hours: 5,500 h/year
- Load factor: 0.75
Saving = (90 - 75) x 5,500 x 0.75 = 61,875 kWh/year = 61.9 MWh/year Total CAE = 61.9 MWh Valuation: 61.9 MWh x 100 EUR/MWh = 6,187 EUR
Important technical considerations
Compressors with an integrated variable speed drive
Next-generation compressors frequently incorporate an integrated variable speed drive (VSD). The saving generated by the integrated drive is counted within the IND090 datasheet; there is no need to also apply the IND240 datasheet. However, if an external drive is installed on an existing compressor without replacing the compressor, the applicable datasheet would be IND240.
Different production capacity
If the new compressor has a different air production capacity (m3/min) than the old one, the calculations must be adjusted in order to compare on a consistent basis. The specific power (kW per m3/min) is used as the basis for comparison.
Compressed air leaks
The repair of compressed air leaks is not included in the IND090 datasheet. Leaks are a genuine saving opportunity, but they are not covered by the standardised datasheets of the current catalogue.
Required documentation
- D1: nameplate of the old compressor (brand, model, rated power, year of manufacture), operating data (hours, working pressure)
- D2: technical datasheet of the new compressor (rated power, specific power, VSD type or not, certifications)
- D3: purchase and installation invoice for the new compressor
- D4: photographs of the old compressor (before) and the new compressor installed (after), with nameplates visible
- D5: supporting calculation of the energy saving
Market potential
The Spanish market has hundreds of thousands of industrial facilities fitted with compressed air compressors. The average useful life of a compressor is 10 to 15 years, which means there is a constant flow of equipment reaching end of life and needing to be replaced. For delegated subjects with access to compressed air installers, the IND090 datasheet represents a predictable and profitable flow of projects.