FEATURE COMPRESSED AIR


HOW TO IMPROVE ENERGY EFFICIENCY


Andy Jones, general manager ofMattei advises on improving the efficiency of compressed air systems which does not necessarily require investing in new equipment


efficiency. Pipe runs need to be suitably designed and laid out as excessive lengths and bends lower system efficiency. Although smaller diameter pipe may save on capital cost greater pressure drops in the system lead to a higher operating cost. The pipework must be checked for


leaks which then need to be repaired. This is a simple and cost-effective exercise (the average cost of a Mattei leak detection survey is less than 10% of the overall leakage costs). We often see compressed air systems with 150 to 300 leaks and a company using 50m3 of compressed air per minute could potentially save around £63,000 by repairing them. Adding heat recovery equipment to the


system can result in further savings. Around 90% of the electrical input used to power a compressor’s motor is turned into heat but approximately 80% can be recovered through a heat exchanger and used for water and space heating. Energy and carbon savings can be


A


joint survey released by the EEF and npower in March 2014 suggests that


Britain’s manufacturers are managing their energy more proactively. A high proportion of businesses (96%) said they were investing in energy efficiency to reduce energy use and address cost with the survey showing that since 2002 the industrial price of gas has increased by 122% while industrial electricity prices have increased by 94%. Almost two thirds of manufacturers cited reducing their carbon footprint as the reason for investing in energy efficiency measures. According to the survey some actions


being taken to manage energy use include energy audits, lighting efficiency strategies and making use of energy specialists and organisations such as the Carbon Trust. When looking to make savings compressed air should be one of the key areas to consider. The industry’s fourth utility, compressors use a lot of energy. Unfortunately however, not all businesses realise the impact that the production of compressed air can have on energy costs and carbon emissions. Before any steps can be taken to


improve the efficiency of a compressed air system it’s essential to carry out an assessment to measure how much compressed air is being used and to


8 SEPTEMBER 2014 | FACTORY EQUIPMENT


ascertain if the compressors, air treatment and pipework delivery system are appropriate for the production processes. We would recommend an initial data logging exercise to evaluate compressed air needs and the efficiency of the system. This involves recording and measuring air consumption profiles over a seven-day period followed by discussions to identify unusual patterns or planned process changes. Some companies including Mattei offer


more detailed energy audits in line with the international standard ISO 11011:2013, Compressed air – Energy efficiency – Assessment. These measures will identify whether improvements can be made to increase efficiency – and this doesn’t always require investment in a new compressor. It could be that environmental factors are affecting air flow and hence efficiency. Cooler air is denser and makes the compression process more efficient so if a compressor is sited near to heat-generating plant or equipment including boilers, furnaces or ovens, the air being drawn into the compressor will be warm and have to work harder, reducing its efficiency as well as the lifetime of its parts. Relocating it could therefore result in savings. Altering pipework can improve


Checking the pipework for leaks and repairing them is a simple and cost-effective exercise


significant, especially if the compressors are operating for many hours. The Carbon Trust suggests that in many cases the cost of recovering warm air can be recouped in less than a year while hot water systems can pay back in less than two. This is likely to be an appealing statistic for manufacturers with the EEF/ npower survey suggesting that payback periods are a barrier to investment in energy efficiency measures. Finally, if data logging and/or an energy


audit reveals that a new compressor would result in significant savings it is essential for the manufacturer to take advice from a specialist. It is important to choose the most efficient compressor rather than the cheapest one available. Some businesses have a misconception that compressed air is ‘free’ once they have invested in the equipment but the main cost will always be the energy required to produce the compressed air. The initial purchase price actually makes up a very small part of the total lifetime costs of the equipment. Energy efficiency is clearly a key focus


for manufacturers and with compressed air being widely used throughout industry improving a compressor’s efficiency can have a big impact on energy costs and carbon emissions. In addition to offering energy efficient compressors Mattei aims to raise awareness about related cost-effective services that could improve efficiency without financing a new compressor.


Mattei T: 01789 450577 www.mattei.co.uk Enter 301


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