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COMPRESSORS & COMPRESSED AIR


COMPRESSED AIR – BUY, RENT OR REPAIR?


When it comes to upgrading your compressor, is it better to purchase a new one outright, repair your existing system or rent a replacement? BOGE's Sales Manager for UK & Ireland, Tom Burton, discusses the options...


s manufacturers report that their electricity bills have more than doubled in the last twelve months, it is essential that your compressed air system is as energy- efficient as it can be. If you find that your system is wanting, you will need to decide whether to purchase a new compressor outright, repair your existing system or rent a replacement. Each year in the UK, over 10 TWh of electricity – equivalent to the output of almost one-and-a- half power stations – is used by manufacturers to produce the compressed air essential for their operations. This is a significant figure, as the UK finds itself in the grip of an energy crisis. According to a survey, undertaken by Make UK in September 2022, nearly six out of ten UK manufacturers (58%) feared that soaring energy prices were threatening their businesses. Nearly half of UK manufacturers (42%) reported that their electricity bills had more than doubled in the twelve months previous, with 32% reporting that the same happened to their gas prices. Over half (52%) expected their electricity costs to at least double again in the following twelve months and 42% feared the same would happen to gas prices. While the UK Government has stepped in to limit the amounts that manufacturers pay for their energy, the caps introduced are still double the prices of October 2021 and there are no guarantees with regard to how long this support will remain in place. Unsurprisingly, some 58% of respondents said


A 12 FEBRUARY 2023 | PROCESS & CONTROL


that they had already adjusted their business practices to cut energy consumption. As part of these efforts, many manufacturers are evaluating their compressed air systems to maximise their energy-efficiency. Those with older systems, however, will have a difficult decision to make. Do they invest in a completely new system, do they make do and mend what they already have, or do they rent a system? All three options have their merits. Lifetime costs: Repair is likely to be the cheapest short-term option if certain parts of your compressor can be easily replaced. Before you take this route, however, it is worth examining the lifetime costs of owning and operating an air compressor. Only around 15% of the total is represented by the initial investment, and 10% by commissioning and maintenance. The balance, around 75%, is taken up by the energy needed to run the system. Opting to repair an older system could be a false economy. Optimal choice: For an air compressor that will be used regularly, purchasing is generally the best option. Indeed, if you have available capital, there has never been a better time to buy an air compressor than now. In the UK, a super deduction tax break enables businesses to reduce their corporation tax liability by 130% of the value of any investment they make in compressed-air systems. Heat recovery: Further, energy-efficiency is


a central element of the designs of most modern compressors. The latest systems, for instance, can be fitted with heat-recovery systems. Using a recovery system, any consumed energy that is converted to heat can be harnessed for other purposes, such as for heating domestic or circuit water, or for process support. Indeed, such systems can recover up to 94% of the heat that the compressor generates. Intelligent control: The use of intelligence control systems, meanwhile, can further reduce energy consumption. Electronic sequential controllers control multiple compressors around a single set pressure, and make them available as needed. So, for instance, instead of using a 100kW compressor at 60% of its output, the system will select two 30kW compressors at 100% of their output. Further gains: Finally, a compressed air system with upgraded drives, motors and speed controls can reduce energy- consumption still further. While fixed-speed compressors are generally cheaper than equivalent variable speed/frequency compressors, any additional capital investment can be recouped rapidly through energy savings. Make do and mend: If sufficient capital is not available, however, then repairing a compressed-air system can still yield significant returns. The leak rate on a poorly maintained compressed-air system, for instance, can reach 40–50% of the generated output, and in certain applications even higher figures have been measured. Indeed, one 3-mm hole in a compressed-air system could cost a business well over £1,000 a year in wasted energy. A well-maintained system should only lose around 5–10% of the compressed air it generates to leakage. Operating at these levels could reduce energy consumption by as much as 20%. Rentals: Renting a compressor might be a good option if the CAPEX for a new system is not available, or if the compressor is needed for short durations, such as to fill a seasonal peak demand, special projects or other temporary situations. Rental costs are typically predictable. Further, rental partners will typically take responsibility for maintaining the system.


While air-compressors can be energy- intensive to operate, we have seen that, whatever your budget, there are steps that you can take to help rectify this issue — saving you money and boosting the profitability of your business.


BOGE bogecompressors.co.uk


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