Energy Efficient Air Compressor System

Abstract

A system and method for compressing a quantity of air is proposed. The air compressor system and method comprises an air compressor for compressing a quantity of air, a supply air fan for supplying air to maintain a pressure set point at the inlet of the compressor, and a static pressure sensor configured to detect the static pressure of the inlet of the compressor. The embodiment also includes a variable frequency drive serving the supply air fan and operable to modulate the speed of the fan to maintain the static pressure at the inlet of the compressor at a set point. An air pressure regulator valve is provided in connection with and operable to regulate the air pressure of the quantity of air. An air pressure receiver stores air to minimize pressure fluctuations. A dryer and air filter are located upstream of said air compressor in embodiments to save energy.

What is claimed is: 
     
         1 . An air compressor system for decreasing the volume and increasing the pressure of a quantity of air having an air compressor formed with an inlet and outlet, said air compressor system comprising:
 a supply air fan connected in electrical communication with said compressor and operable to maintain a pressure set point at said inlet of said compressor;   a static pressure sensor connected in electrical communication with said compressor and configured to detect a static pressure at said inlet of said compressor;   a variable frequency drive connected in electrical communication with said supply air fan and configured to modulate the speed of said fan to maintain said static pressure at said inlet of said compressor.   an air pressure regulator valve in connection with said compressor and operable to regulate said air pressure of said quantity of air;   an air pressure receiver configured in electrical communication with said air pressure regulator valve and operable to store air for minimizing a fluctuation in said pressure;   
     
     
         2 . The air compressor system of  claim 1 , wherein said air compressor is injected with a lubricant. 
     
     
         3 . The air compressor system of  claim 2 , further comprising an air separator configured in communication with said compressor and operable to separate out said lubricant from said quantity of air. 
     
     
         4 . The air compressor system of  claim 2 , further comprising a coalescing separator configured in communication with said compressor and operable to separate said lubricant from said quantity of air. 
     
     
         5 . The air compressor system of  claim 2 , further comprising a lubricant cooler configured in communication with said compressor and operable to cool said lubricant. 
     
     
         6 . The air compressor system of  claim 1 , further comprising at least one air filter connected upstream of said air compressor and operable to remove undesired matter from said quantity of air. 
     
     
         7 . The air compressor system of  claim 1 , further comprising a dryer configured upstream of said air compressor, said dryer having a drying agent for removing moisture from said quantity of air fed through said outlet of said air compressor; 
     
     
         8 . The air compressor system of  claim 7 , further comprising an air by-pass damper connected in electrical communication with said compressor and configured to enable said quantity of air to bypass said damper. 
     
     
         9 . A method of decreasing the volume and increasing the pressure of a quantity of air, said method comprising:
 providing an air compressor formed with an inlet and outlet in contact with said quantity of air;   compressing, by said air compressor, said quantity of air;   providing a static pressure sensor in connection with said compressor;   detecting, by said static pressure sensor, a static pressure of said quantity of air;   providing a supply fan in electrical communication with said compressor;   maintaining, by said supply fan, a pressure set point at said inlet of said compressor;   providing a variable frequency drive in electrical communication with said supply fan;   modulating, by said variable frequency drive, a speed of said fan to maintain said static pressure at said inlet of said compressor at a set point.   providing an air pressure regulator valve in connection with said compressor;   regulating, by said air pressure regulator valve, said pressure of said quantity of air;   providing an air pressure receiver in communication with said air pressure regulator valve;   storing, by said air pressure receiver, said quantity of air.   
     
     
         10 . The method of  claim 1 , further comprising providing at least one air filter upstream of said compressor, and removing, by said air filter, undesired matter from said quantity of air. 
     
     
         11 . The method of  claim 1 , further comprising injecting said compressor with a lubricant. 
     
     
         12 . The method of  claim 11 , further comprising providing a lubricant cooler in communication with said compressor and cooling, by said lubricant cooler, said lubricant. 
     
     
         13 . The method of  claim 11 , further comprising providing a coalescing separator in communication with said compressor and separating, by said coalescing separator, said lubricant from said quantity of air. 
     
     
         14 . The method of  claim 11 , further comprising providing an air separator in communication with said compressor and separating, by said air separator, said lubricant from said quantity of air. 
     
     
         15 . The method of  claim 1 , further comprising providing a dryer configured upstream of said air compressor and removing, by said dryer, moisture from said quantity of air at said outlet of said compressor. 
     
     
         16 . The method of  claim 15 , further comprising providing an air bypass damper in connection to said compressor.