PC-NOV23-PG16-17.1_Layout 1 14/11/2023 09:29 Page 16
COMPRESSED AIR HOW TO REDUCE COMPRESSED AIR COSTS
Gareth Lees, Optimisation Manager, Atlas Copco Compressors offers seven recommendations to help curb energy use when compressing air
energy can deliver big savings. Controlling energy usage can also deliver production efficiencies, contributing to a more sustainable business operation. About 10% of the world’s energy is used for
R
compressing air, so this should be a prime focus for any business wanting to reduce its carbon footprint. In addition, energy represents around 80% of the lifetime cost of your compressor, so compressed air efficiency is the number one priority to substantially reduce your operational costs. Here are the seven recommendations to
reduce energy usage. Some are easy and quick to implement. Others require some investment, but the energy savings mean the interventions will quickly pay for themselves. 1. Reduce your air pressure Reducing air pressure not only saves energy
and reduces cost, but can also extend the maintenance intervals for seals or diaphragms because they will be subjected to less stress. If your compressed air system produces 10 bar of pressure but it only takes 7 bar to power your equipment, then you are wasting 3 bar. That might not seem like a lot, but the impacts are cumulative. For every bar that you lower the pressure of your compressed air system, your energy consumption will go down by about 7%. Frequent evaluation of your system requirements will deliver the best results. If you own multiple compressors, consider
using a smart central controller, which will ensure that each compressor delivers the correct pressure to multiple applications (if the applications require different pressure setpoints). This solution also eliminates pressure reducers, which would otherwise waste energy. Another way to reduce your pressure setpoint is to review your air
educing energy consumption has never been more important. With energy prices at an all-time high, using less
distribution system. Small diameter piping, excessive bends, couplings, filters, and pressure reducers have a big impact on the total pressure drop of a system. Seek opportunities to increase the diameter where necessary, remove pressure reducers and increase the size of installed filter packages. And don't forget to reduce your pressure setpoint to enable those savings afterwards. 2. Eliminate air leakages Almost every compressed air system has
leaks – and these can be very costly. Most compressed air users do not realise that up to 30% of their energy – and an average of 20% – is lost due to leaks in their piping. Quite literally, this is your money vanishing into thin air. There are many ways to pinpoint leakage.
They range from sophisticated scanners to low-technology methods. For example, you can simply apply soapy water to areas in which you suspect leaks. If there is a leak, you will see the formation of bubbles. Another
compressor room make a major difference to equipment performance
“ The conditions in your
simple solution is to isolate unused tools to eliminate leaks inside this equipment. The most accurate method is using ultrasonic air leak detection equipment. This doesn’t interrupt plant operation, reaches system areas that are hard to access, and locates all air leaks and reports the results, allowing maintenance teams to quickly locate and prioritise repairs based on the severity of the leaks. 3. Optimise your ambient temperature Ambient temperature plays a major role in
”
keeping your energy bill low. For every reduction of 5°C, you can achieve energy
savings of 1.5%. Indeed, the conditions in your compressor
room – or the room in which your compressor is located – make a major difference to the performance of the equipment. Make sure that you run your compressors in clean, cool, and well-ventilated environments. Keep the air in the room free from dust and moisture to ensure that the compressed air is not contaminated and doesn’t have to be treated more than necessary. Eliminating the need for aftercoolers, dryers and filters also saves energy. Get your intake air from the outside, especially in cooler environments. 4. Perform regular maintenance Regular check-ups and energy audits not
only extend the lifespan of your compressed air equipment but also help make it more efficient. This type of maintenance optimises the performance of the entire system, which reduces the amount of energy it consumes. Regularly replacing wear parts will reduce leaks, while periodic inspections will help detect them. But don’t just wait to perform maintenance
when it is scheduled. Many tools and technologies are now available that will allow you to carry out predictive and preventive maintenance to keep your compressors in the best possible working order. 5. Respect the service life of your machine No matter how well you maintain your
compressed air equipment, its effectiveness and efficiency will diminish over time. Hanging on to older machines is a false economy because they get more expensive to operate – both in terms of energy consumption and upkeep costs. In addition, you will fail to take advantage of the improvements that are being made all the time in compressor technology, such as the evolution of variable speed drive (VSD) technology. When launched 25 years ago, Atlas Copco’s
variable speed compressors offered energy savings of 35% over conventional fixed-speed compressors. The latest version of these compressors – the GA VSDs series – can reduce your compressor’s energy consumption by up to 60%. So, while some businesses may not want to make new investments in the current economic climate,
16 NOVEMBER 2023 | PROCESS & CONTROL
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58
