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COMPRESSORS & COMPRESSED AIR
advantage of measures such as heat recovery represents a considerable opportunity to lower energy costs, by recycling excess heat and using it to a site’s advantage. With typically only 10 per cent of the electrical energy input being converted into compressed air, the remaining 90 per cent is generally wasted as heat. By fitting a heat recovery unit to a compressor, the system can ‘recapture’ energy lost during the compression process and use it for other useful purposes. Drive improvements with digital insights:
The Internet of Things and data analytics can help operators to understand how efficiently a compressor is running, and whether any improvements can be made. These insights will not only help highlight any potential issues now, but also enable operators to forecast any future problems, based on deteriorating machine performance. Predictive maintenance models based on
real-time data can be established to help reduce energy consumption, improve process efficiencies and limit any risks. Connectivity continues to be a key focus in the CompAir portfolio, with the company’s iConn service
SAVE ENERGY AND PROTECT THE ENVIRONMENT
Now is an opportune moment to take advantage of heat recovery, oil-free technology and digital analytics, says CompAir
much as 40 per cent of all the industrial energy consumed1
W
ith Europe experiencing soaring energy prices, and compressed air accountable for between 12 to as
, many businesses are
considering what steps they can take to minimise costs and improve the efficiency of their operations. In the first quarter of 2022, short-term gas
prices on the largest European exchange were five times higher than their 2021 average2
, and future markets are pricing
European gas at up to three times its 2021 levels for at least the next three years. CompAir is advising compressed air users that action can be taken now to help protect future investments. Here are some top tips: Opt for oil-free screw compressors: While
most production-sensitive environments, such as those in the food and beverage or pharmaceutical sectors, will opt for an oil-free compressor, many other businesses would benefit from the efficiencies that an oil-free model can deliver. In many cases, whole life costs are reduced, with businesses able to save on the cost of oil replacement, and there’s no requirement for additional products such as oil separators. CompAir offers a wide range of oil-free
compressor technologies, including screw and piston machines. Its advanced Ultima compressor operates completely oil-free, with the cooling of components achieved via a closed water circuit.
0 Take advantage of the latest oil-lubricated
screw compressor technology: However, for those seeking an upgrade to an oil-lubricated system plus air treatment, the latest oil- lubricated technologies have been developed to optimise sustainability throughout the compressor’s lifecycle. CompAir’s FourCore range combines compressed air efficiency with a small footprint and sustainable design for eco-conscious businesses. For example, when carbon emissions from a
new 160 kW FourCore model are compared with a traditional compressor, running for 8,000 hours a year, the FourCore system reduces the equivalent greenhouse gas emissions of 32 passenger cars, or 371,800 miles driven by a passenger car, over the course of one year. This is the same amount of carbon sequestered by 181 acres of forest. Treat air correctly: Modern production
systems and processes demand compressed air of ever-increasing purity. The proper specification of downstream equipment will not only improve the quality and efficiency of a compressed air system, but reduce its environmental impact too. CompAir offers a wide range of compressed
air treatment solutions including filtration, refrigeration and absorption dryers and condensate management systems. High- quality consumables, such as filter elements with a long service life, ensure low component wear and consistently low differential pressure. Heat recovery:Meanwhile, taking
6 JULY/AUGUST 2022 | PROCESS & CONTROL
offering intelligent insights that help operators monitor a system’s performance in both real- time and remotely. Guaranteed assurance with service
agreements: To help companies avoid unplanned and unbudgeted downtime, as well as production interruptions, CompAir has launched a series of new Assure service agreements. Available to all compressed air users, no matter the manufacturer or age of the equipment, these help businesses optimise operational efficiencies, mitigate risks, and streamline working practices by ensuring customers only need to deal with one compressed air supplier. Don’t leak profit: It’s essential to manage
pipework leaks. A solution is a simple leak detection survey, which can identify any problems quickly so remedial action can be taken. Alternatively, a flow meter can evaluate compressed air generation and downstream inefficiency costs. Undertake an energy audit: Whether it’s
buying a new compressor or upgrading an existing system, a sensible starting point is to always undertake a full site energy audit. This will establish current compressed air usage and costs, help identify air leaks to determine where energy is being lost and where cost savings could be made, and test air quality to ensure the compressed air generated meets
the right standards. 1
British Compressed Air Society 2McKinsey, ‘Outsprinting the energy crisis’,
https://www.mckinsey.com/business- functions/operations/our-insights/outsprinting-the-en ergy-crisis
CompAir
https://www.compair.com/en-gb/sustainable- compressed-air
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