Compressed Air Systems
Compressed air is versatile and reliable, and is used
in a variety of wide-ranging applications. However, it
can be expensive to produce when the compressed air
system operates inefficiently. Only 10 to 20 percent of
the energy required to generate compressed air ever
reaches the point of use. Remaining energy is rejected
in the form of wasted heat, making it critical that your
compressed air system is as efficient as possible.
A study by the U.S. Department of Energy suggests
that more than 50 percent of industrial compressed air
systems could see significant energy savings through
low-cost improvements. The typical manufacturing
facility could reduce total or system energy use by 17
percent by installing energy efficiency improvements
with simple paybacks of three years or less. By taking
advantage of MidAmerican Energy Company’s
EnergyAdvantage® incentives, project paybacks can
be even more attractive for your business.
SAVE SOME GREEN –
REALIZE EFFICIENCY WITH YOUR
COMPRESSED AIR SYSTEM
To improve and maintain your compressed air
system performance, it is important to address each
component, and to analyze both the supply and
demand sides of the system and how they interact.
MidAmerican Energy’s EnergyAdvantage programs
offer incentives and expert advice on implementing
energy efficiency measures at your facility. Our
EnergyAdvantage programs have helped customers
identify more than $1,000,000 in compressed air
energy-savings project opportunities that have the
potential to save customers an average 5 percent on
their facility’s energy usage. Typical energy efficiency
measures include:
Reducing Overall System Demand
To reduce overall energy consumption, all critical
compressed air end-uses should be identified,
including the demand and pressure requirements
of each. If an application can be powered more
efficiently by alternative methods, these methods
should be identified and considered.
Minimizing Leaks
As much as 20 to 30 percent of a compressor’s
output can be wasted through system leaks.
Fortunately a leak assessment can be very cost
effective, and minimizing leaks can drastically
reduce system demand requirements. Identifying
and repairing leaks can reduce run time, increase
equipment life and reduce maintenance.
Improving Controls
Improving controls is one of the most cost-effective
energy efficiency improvements for a compressed
air system. Compressed air system controls can
optimize the compressed air supply with the system
demand by shutting off unneeded units or activating
additional units to meet demand. In general, the
more machines in the system, the more opportunity
for realizing energy savings from improved controls.
www.midamericanenergy.com/ee
Optimizing System Pressure Setpoint
Using more pressure than is required to run
equipment increases energy consumption and
compressed air costs. Reducing the system supply
pressure in small increments can determine if a
system’s pressure is set higher than optimal. For
every 2-psig reduction in compressor discharge
pressure, compressor energy use can be reduced by
1 percent.
Installing High-Efficiency Air Nozzles
High-efficiency air nozzles can reduce compressed
air consumption by projecting a precise jet of air
for blow-off applications. Installing high-efficiency
air nozzles can reduce compressed air application
demand by 50 percent or more and also can
reduce perceived noise levels.
Nonresidential Energy Savings
MidAmerican Energy’s customers who have
completed energy efficiency measures through
the EnergyAdvantage nonresidential programs
have seen favorable paybacks and savings. The
energy efficiency measure savings have been up
to $20,000, with paybacks as shown in the table
below. Paybacks are shown without incentives, and
incentive eligibility for these measures may vary.
Contact MidAmerican Energy for details.
Energy Efficiency Measure
Paybacks
Less Than
Repairing leaks*
1.5 years
Improving controls
3 years
Optimizing pressure setpoint
2 years
Installing No-Loss Condensate Drains
Installing high-efficiency air nozzles
1 years
Removing condensate is important for maintaining
the appropriate air quality level. However,
significant energy can be wasted if condensate
removal is done with timer drains or cracked-open
valves. By installing a no-loss condensate drain,
compressed air is saved and air quality levels are
improved.
Installing no-loss condensate drains 1 years
NEXT STEPS AND AVAILABLE
FINANCIAL INCENTIVES
MidAmerican Energy’s EnergyAdvantage programs
are designed to put the power of energy efficiency in
the hands of our residential and business customers.
For business customers interested in increasing
the efficiency of their compressed air systems, the
Nonresidential Custom Systems and Nonresidential
Energy Analysis programs are available.
To learn more about MidAmerican Energy’s
EnergyAdvantage savings or energy efficiency
improvements, call your MidAmerican Energy
representative at 800-894-9599 or visit
www.midamericanenergy.com/ee.
* Repairing leaks is an extremely cost-effective energy efficiency
measure; EnergyAdvantage incentives are not available for this
measure.
RESOURCES
The Advanced Manufacturing Office
www.eere.energy.gov/industry/bestpractices
AIRMaster+
www1.eere.energy.gov/manufacturing/tech_
deployment/software_airmaster.html
U.S. DOE Compressed Air Tip Sheets
www1.eere.energy.gov/manufacturing/tech_
deployment/compressed_air.html
The Compressed Air Challenge
www.compressedairchallenge.org
QUESTIONS?
Call MidAmerican Energy at 800-894-9599 with questions about application procedures, qualifying
projects, incentives or verification procedures.
www.midamericanenergy.com/ee