Energy Savings Through Tank Storage

Case for Installing Tank Receiver 

Although there isn't a simple way to determine how much money you will save by installing a larger receiver tank than before, the logic behind it is quite simple. A receiver tank has one major advantage: it requires very little maintenance and consumes no energy.

Switching from Idle to Load

Fixed-speed compressors, such as Kaeser and others, use their full motor horsepower (and therefore full kilowatt draw), when they are fully loaded and producing compressed air. The machine will switch from idle to load when it reaches the set pressure. It reduces its power consumption by 60% when it is idle.

Let's demonstrate this by using a Kaeser CSD compressor with 75 horsepower fixed speed:

• 75 HP equals 55 kW.

• A 75-hp Kaeser compressor can run at 55 kW under full load. It consumes 22 kW when it is idle.

• The plant will operate for 8,000 hours annually, and the power consumption is $57,200 (55kW x 8000 hours x $0.13 energy).

• Without a receiver tank, the loaded hours are approximately 20,600

• The hours without the use of a receiver tank is 31,000.

• This shows that the load power decreases by 60% when we switch off the load for 32 percent of the time.

It is evident that increasing the time that a compressor runs idle can help reduce electricity costs.

Increasing Tank Size

An increase in tank size can lead to even greater energy savings. A 660-gallon storage tank can be increased to 1,060-gallon capacity. This will increase the idle time by 62%.

This example is for a fixed speed compressor. A tank equipped with a variable speed compressor will not result in the same energy savings as a tank that has a fixed-speed compressor. However, it will increase idle time.

Additional Benefits

A receiver tank can be added to any compressed-air system. This will allow you to save time and maximize your productivity.

A Kaeser compressor automatically switches to idle when it is set by the factory. It then engages a 4-minute run-out timer. The compressor will automatically stop if no compressed air is needed within the 4-minute time limit. The goal should be to get the compressor running on time. This is why we say, "You can never have too much storage."

The tank also acts as a buffer to the compressor's control valves. This prevents premature wear and tear on the valves and reduces cycle times.

The tank slows down the speed of air and creates a cyclonic motion when the air passes through. This reduces the oil/water condensation load on downstream clean air treatment filters, dryers, and further reduces maintenance costs.

This sums up the cost-benefit analysis for adding or increasing a receiver tank. If you have any questions, please let us know. We would be pleased to visit your site and make recommendations to optimize your compressed air solutions to reduce ownership costs.

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