High effic idea for compressor set up

[Danglerb]

I'm wondering if this is done, might work or be practical.

Air compressor with on/off at 120/160 feeds two tanks each with inline check valves, big tank has regulated output 110 psi with output to a Y from the small tank and then a final regulator to 100 psi or whatever shop pressure is.

No load both tanks fill to 160 psi.

Modest load the air comes from the smaller tank, when the compressor kicks on it sees a 120 psi head until the small tank comes up to 160 psi.

100+% of compressor output load, head is the small tank pressure, and big tank maintains min pressure to shop regulator.

Size of the two tanks and exact pressures adjusted to balance lower head pressure vs cycling frequency. Some kind of smart controller could also set min time between compressor starts forcing use from the big tank when cycle time is below the min.

 

[GingerKid]

I don't really see it being any more efficient. The compressor might run longer, but less often with your setup since you have two tanks with more volume, but if your air tool uses X cfm, sooner or later the compressor has to do the same work to compress that X cfm

 

[Danglerb]

The difference is the head pressure the compressor sees, which determines the load on the motor, and with a smart drive circuit like power factor correction, lower load uses less electricity.

Thinking more about the key would be to have a smart variable speed controller for the compressor motor that matched the speed to the current air use.

Late night ideas ....

 

[eddiemeddiem]

In theory, it would work pretty good. I'd run a PID controller based on tank pressure to control a VFD running your compressor motor. With the VFD, you shouldn't need PFC.

Now finding/assembling all the right components is a different story...


Sent from my iPhone using Tapatalk

 

[md21722]

Pressuring up to 160 psi, you are into dual stage compressors, which generally have a very linear output all the way to 175 psi. Single stage compressors start slowing down after about 110 psi. This why you'll see dual stage compressors may be 17.7 CFM @ 90 psi and 17.5 @ 175 psi but single stage compressors are rarely rated over 90-100 psi. A single stage compressor that makes 6.4 CFM @ 90 PSI may only produce 4 CFM @ 130 PSI.

 

[larry_g]

The difference is the head pressure the compressor sees, which determines the load on the motor, and with a smart drive circuit like power factor correction, lower load uses less electricity.

Thinking more about the key would be to have a smart variable speed controller for the compressor motor that matched the speed to the current air use.

Late night ideas ....

What you are describing is exactly what I use on my well pump. In the well pump industry they are called constant pressure pumps. The further the pressure is from the set point the faster it spins the pump. No reason it couldn't work on an air compressor.

lg
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