FEATURE ENERGY MANAGEMENT
EASY STEPS TO MAXIMISE ENERGY EFFICIENCY
reduction. A 1 bar drop in system pressure could potentially result in a seven per cent cost saving on electricity. An alternative approach to a full pressure system might be to use a multi-pressure system or smaller booster compressors where needed to maximise savings.
by Mark Whitmore, general manager, BOGE UK C
ompressed air is almost universal in commerce and industry across the
world we live in today. Across the continent, compressed air usage is calculated at around 80 TWh a year, and in the UK alone that adds up to an impressive 10 TWh and more being used annually. In a typical manufacturing plant compressed air production can amount close to a third of the total electricity usage. Most modern air compressors offer
high mechanical efficiencies. However, according to figures from the UK’s Carbon Trust the overall efficiency of a typical compressed air system can be as low as 10-15 per cent. Although initial capital costs account
for just about 15 per cent of total expenditure for a typical air compressor, compressed air is certainly expensive to produce. Over its operational lifespan, energy can account for as much as 75 per cent of total expenditure. Despite the high operational cost of producing compressed air, many systems are very inefficient and wasteful and that can lead to a significant bottom line impact. There’s also a considerable carbon
footprint associated with compressed air production. Carbon Trust figures indicate the sector is responsible for more than five million tonnes of CO2 emissions annually. But, by adopting a series of simple strategies to mitigate leaks, improve
12 AUGUST 2019 | IRISH MANUFACTURING
maintenance, and address poor control, use and misapplication, operators can in fact make big savings on energy use and dramatically reduce their climate change emissions.
TIP 1: REDUCE LEAKS Systems which are poorly maintained can leak a staggering 40-50 per cent or more of the compressed air produced, therefore addressing leaks can drastically reduce energy loss. Estimates suggest 20 per cent savings may be possible here. Ultrasonic leak detection equipment is beneficial - even a single 3mm hole could potentially result in wasted energy costing well over a £1000 annually.
TIP 2: GETTING THE MOST FROM COMPRESSED AIR Compressed air is an expensive commodity which should be used sparingly. It is possible that alternative solutions could potentially result in greater efficiency. Blow guns can use as much as 30 per cent less air if fitted with venturi- type nozzles and by changing filters on a regular basis, operators can also benefit from better system efficiencies.
TIP 3: REDUCE SYSTEM PRESSURE Usually running unnecessarily at full pressure - somewhere in the region of 100 psi (7 bar) - a compressed air system would certainly benefit from pressure
BOGE
https://uk.boge.co m/en T: +44 (0) 1484 719 921
A well-maintained compressed air system will undoubtedly still produce some air leakage, but on average a loss of 5-10 per cent, even on a new system, would be considered acceptable
TIP 4: SYSTEMS EFFICIENCY UPGRADE Savings of three per cent could be made on electricity bills from improving system efficiency, by increasing pipeline diameters and reducing frictional losses. Big savings can be made when the compressor unit is optimised and even in its idle state, a fixed-speed compressor can consume 20- 70 per cent of its full load. By enhancing the compressor drive, improved motor efficiency and better speed control is achievable. Alternatively, a compressor unit upgrade is also an option, the energy savings in some applications could easily offset the capital expenditure. Recovering the heat generated during a compression cycle as well as improving cooling, drying and filtering are where other cost savings can be made.
TIP 5: MORE SOPHISTICATED CONTROLS Optimising system controls can also enhance the compressor unit’s efficiency. From adapting to work loads, controlling various stages of the compressor unit when needed, to delivering accurate pressures on demand, such systems might benefit from the use of several smaller pumps, as opposed to a single larger unit, for example. Compressor availability will still match the demand as near as possible, but the result is more energy savings. Predictive maintenance, remote system analysis, monitoring systems, auditing, along with other optimisation developments, are also by increasingly enabled by emerging state- of-the-art Industry 4.0 technologies. Compressing air is not cheap but it is
essential for many industries. With policymakers putting more pressure on large energy consumers to tackle their carbon footprints, along with electricity prices rising, the cost of compressed air is only likely to increase. Curbing energy consumption wherever
possible is crucial and big dividends can be achieved by improving compressed air efficiency. A system that's energy efficient is as important now as it is for the future.
/ IRISHMANUFACTURING
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
