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Feature Compressed air
Compressing industry’s energy costs
energy to create the same amount of
air, providing practical advice and
ensuring compressed air is used effi-
ciently. Brammer has conducted com-
pressed air surveys for customers
across a range of industries, often
identifying savings that can amount to
thousands of pounds per year in
reduced energy costs.
Every leak in a compressed air
system produces a sound pitch which
is often impossible to hear with the
human ear over the background of a
noisy factory. However, this output
can be detected and read by ultra-
sound equipment, with each leak
tagged and numbered.
Quantifying savings
By calculating the running conditions
of the compressors (length of time
operational each week), electricity
cost, the pressure of the compressed
The process of compressing air can be highly wasteful,
air system, and compressor generation
efficiency, the cost of the leak – and
yet companies have historically failed to address the
thus the potential cost savings created
by repairing it – can be fully quanti-
reasons for this waste. Ian Ritchie, managing director of
fied, by machine, department, area or
Brammer UK, explains how regular, thorough maintenance
even factory.
This data can be presented in a
can help reduce air leaks, and drive down energy costs in
dynamic document which, as leaks are
fixed, is updated accordingly. Ongoing
compressed air production
monitoring can also be provided by fit-
ting an air flow meter to the system
C
ompressed air is vital to a multi- over a 10 year period, it is easy to see before the air preparation equipment.
tude of manufacturing processes how regular, thorough, maintenance This ensures a proactive approach to
– yet the process of compressing can help drive down energy costs in Ian Ritchie says dealing with future leaks – by immedi-
air can be highly wasteful. More compressed air production. savings can be ately identifying any increases in air
than 10% of electricity supplied to In fact, reducing air leaks is com- made by examining usage which can then be investigated
industry is used to compress air – monly the single most important all applications, and remedied.
whether for cooling, drying, removal energy saving action for many sites. and establishing
of scrap product, removal of contami- When the cost of all leaks and wastage whether com- Looking for alternatives
nation, or vacuum generation. In some due to inadequate maintenance is cal- pressed air is actu- Further savings can be achieved by
cases, it is up to 30% of total energy culated, the outlay for detection equip-
ally needed at all
examining all applications and estab-
usage, yet of the total energy supplied ment and replacement parts is almost lishing whether compressed air is
to a compressor, as little as 8–10% always justified. actually needed at all. Using com-
may end up being converted into pressed air for drying, for example, is
usable energy to power equipment, Interrupting production often costly compared with blowers,
making it a costly energy source. Not only do leaks present safety issues or even using the rejected heat from
Leaks, poor maintenance, misappli- through blowing air and noise, they the plant compressor. Electrically
cation and poor control are all areas can interrupt production due to equip- powered angle grinders are also often
where compressed air is commonly ment failure and create additional more efficient than their compressed
wasted. However, many companies costs because of fluctuating system air driven counterparts. Compressed
have failed to address these areas and pressure, reduced service life and air is also used as a means to blow
not taken the necessary steps to opti- increased maintenance, and the swarf, dust or shavings from machin-
mise efficiency in compressed air pro- requirement for excess compressor ery – a solution which may be quick
duction and usage, and ended up capacity. and easy but is not low in cost.
facing higher energy bills as a result. Leaks can occur in hoses and cou- Developing a compressed air usage
plings; pipes, flanges and pipe joints, policy in conjunction with an expert
Overuse and pressure regulators; manual con- equipment supplier, combined with
Compressed air is often overused, densate drain valves and shut-off regular planned maintenance based
partly because it is convenient and valves which are left open; and from around comprehensive audits, can
easy to use, and partly because air is air-using equipment left in operation dramatically reduce compressed air
often perceived as a free commodity. when it is not needed. usage – and energy costs.
However, with maintenance typi- Compressed air audits can help
cally accounting for as little as 7% of manufacturers improve energy effi-
Brammer
the total costs of running a compressor ciency – by removing leaks, using less
www.brammer.biz Enter 203
10 JUNE 2009 Process & Control
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