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COMPRESSORS & COMPRESSED AIR
10 STEPS TO GREENER PRODUCTION
Energy reduction is the only way to a carbon-neutral economy, and according to Atlas Copco, it can start with compressors
he 10 steps to greener production in this guide can be taken right away and cost little. They are part of a continuous process to maintain peak production efficiency.
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Step 1: Matching equipment to applications Companies waste up to 50% of the power needed to generate compressed air through inappropriate use or inefficient systems design. In many cases, they may be able to invest in smaller, cheaper equipment, as long as they have eliminated inefficiencies as follows: 1) Isolate equipment when it is not in use. Use a simple manual isolation valve or an electronic valve to reduce equipment leakage. 2) Keep cool. Compressed air equipment should be installed in the coolest location in the facility, and heat generated should be removed from the compressor room. Every 5°C rise in air temperature results in a 2% loss in efficiency. 3) Keep clean. Dust in the air will block filters. Every 3 millibar pressure drop in the intake filter increases power consumption by 1%. 4) Keep working pressure as low as possible. A higher working pressure means a higher power requirement, higher energy costs and a larger carbon footprint. Step 2: Storage and distribution Air receivers reduce the cycling time of air compressors, which increases their reliability and longevity. A larger air receiver can reduce power consumption. Consider separate compressed air systems if the majority of the production requires a lower
16 FEBRUARY 2022 | PROCESS & CONTROL
pressure than the highest pressure requirement.
Companies often simply extend their pipework to meet the needs of new equipment, but this can cause pressure drops. Three inexpensive ways to address this are: 1. Increase the main distribution pipework diameter. This will enlarge the stored volume and also reduce air velocity and pressure drop. 2. Convert a dead-end or single pipework system into a ring-main pipework system. This increases volume and lowers the pressure drop. Lowering pressure differential by 0.5 bar can reduce the energy consumption of a compressor by up to 4%.
3. Plug the leaks. The average production facility loses up to 20% of the compressed air it generates to leaks.
Step 3: Know air purity requirements. Treating compressed air costs energy and money, so it is important to know the level of air purity required (see table below). Atmospheric air contains water vapour and dust. When that air is compressed, the concentration of these contaminants also increases, and they must be filtered out to protect equipment and maintain the required level of air purity. Step 4: Understanding air demand It is important to be aware of peak production periods and times of lower air demand. With a good understanding of
The ISO 8573.1: 2001 table defines the various air quality classes
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