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FEATURE COMPRESSED AIR


THE ROLE OF COMPRESSED AIR SYSTEMS in green production


By Alexander Pavlov, General Manager, Atlas Copco Compressors UK


An overwhelming majority of scientists and numerous studies tell us that the planet is warming at a rate that will radically change how we live on it


S


ince 10% of global electricity consumption goes to generating compressed air, air compressor manufacturers can make a real difference by developing solutions that make compressing air more energy- efficient and that support manufacturers in their journey towards carbon-neutral production. Energy costs make up 80% of a compressor’s total cost of ownership. Investing in environment-friendly compressors and optimising existing air systems that use significantly less energy can sharply reduce the production cost of compressed air and a company’s carbon footprint. Green air compressors guarantee that a company will lower the production cost of compressed air, protected from fluctuating energy prices. A green compressor offers greater reliability, longer maintenance intervals and ensures compliance with all current and upcoming emissions standards. The Total Cost of Ownership (TCO) of a compressor consists of the cost of buying, owning and operating it during its lifetime. Because of manufacturers’ technology developments embodied in advanced, environment-friendly compressors, these units may carry a higher price tag, but offer much lower operating costs, providing payback in the long run. The initial investment constitutes only a small fraction of the TCO. Energy costs


16 APRIL 2021 | IRISH MANUFACTURING


make up the bulk of it and will likely become an even more important issue if energy prices continue to rise despite evident progress in, and nationwide dependence on, sustainable alternative energy sources.


ENERGY EFFICIENT If an application requires a constant speed at all times, a fixed-speed compressor is the best choice. Once it is switched on, it gives full power. Most industrial applications, however, have a fluctuating air demand, meaning a variable speed drive (VSD) compressor is the better choice because it matches the output to user demand and will realise considerable energy savings in the long run. A VSD or VSD+ compressor will reliably deliver top-quality air while lowering energy consumption by an average of 50%.


Compressors generate heat. Most businesses allow it to dissipate as quickly as possible to keep the ambient temperature down. However, purchasing a compressor with integrated energy recovery, or installing a heat recovery system between the compressor and the cooling and heating circuits, will recover and re-use 70-94% of the energy required to run a compressor. The hot water recovered, and heated up to 90o


C,


can be used for sanitary purposes and space heating but is particularly suitable for process-heating applications. Neglecting a compressed air system


Atlas Copco


www.atlascopco. co.uk/compressors


invariably leads to costly inefficiencies, so they should be regularly maintained, continually monitored and carefully controlled. While supplier’s scheduled maintenance plans should be mandatory, the best way to manage a compressed air system is to install a state-of-the-art master control system that monitors its efficiency, availability and reliability. Not only can it detect problems, but it automatically reduces the working pressure – and energy costs - when air demand is low. For businesses where it is critical to meet extremely high standards in their processed air requirements, green technology should only be employed if it guarantees that final products are not compromised. It can be argued that for applications such as clean rooms in pharmaceutical production, food and beverage production, or electronics manufacturing, maintaining stringent quality standards is much more important than using the most environment-friendly equipment. To protect sensitive processes, premium air treatment equipment, such as oil-free compressors that are ISO 8573-1 Class 0 certified, produce high air quality, free of oil vapours, aerosols and other contaminants.


GOING GREEN An overwhelming majority of scientists and numerous studies tell us that the planet is warming at a rate that will radically change how we live on it. Natural disasters are already gaining in strength, giving even more reasons for compressor manufacturers to develop solutions that help customers become carbon-free, and for production companies to embrace the material benefits of green technology, together fighting against climate change.


/ IRISHMANUFACTURING


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