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COMPRESSED AIR
The efficiency of UltraPleat technology can be maximised by flow-optimised filter housings, combined with continuous monitoring through an economiser. This monitoring system not only indicates the most economical replacement time for the filter but also provides data for higher- level control of compressed air systems. For applications with larger compressed air
volume flows, UltraPleat filters are fully optimised while remaining scalable. This ensures a prolonged service life with consistently low differential pressure, a vital factor for achieving energy savings. Ultrapac Smart adsorption dryer technology
incorporates UltraPleat filters too, along with capacity control and compressor couplings that contribute to substantial savings in regeneration air. Additionally, energy-efficient alternatives in dryer technology comprise prefilters equipped with electronic, level-controlled drains, intermittent operation standards, zero purge technology, and energy-saving control systems such as Ultraconomy.
STOP THE LEAKS But even the very best filter technology can’t generate miracles. Pipe connections, conditioning units, shut-off valves, quick couplers and terminal equipment are all common sources of small air leaks that add up to a flood, with 25 per cent losses before air reaches the application being common. For a company operating a 150 kW compressor for 6,000 hours a year, that can mean almost £50,000 is needlessly wasted. Unlike natural gas, a small air leak can
easily go relatively unnoticed. The first response is often to increase the system
pressure which has the potential to result in a significant annual financial loss. Unplanned changes in ΔP also indicate changes in the filters, with pressure drop increasing as contaminants build up, and a sudden dip in that level being a potential sign of a leak or rupture. Regular servicing and preventive maintenance are therefore essential for cost-effective operation – and Donaldson can apply the same state-of-the-art technology and techniques it uses so successfully at its own facilities to help detect leaks and minimise energy costs (as well as conduct Air Quality Audits) at the sites of its customers too. Even leaks as small as 0.1 lpm can be identified, while the plant is operating normally, as the company’s experienced customer service engineers check the entire piping system and terminal equipment. Sometimes only small adjustments are needed, such as tightening a tube connection, sealing a leaky pipe, or repairing a conditioning unit. A detailed report is produced, containing all
necessary information for the elimination of the leaks, the size of the leakages and the
financial and CO2 savings potential per leak. An optimisation concept can then be tailored to your specific needs. “Better energy management is one of our priority sustainability goals as we target an absolute reduction of greenhouse gas emissions by 42 per cent by the end of FY30 from a FY21 baseline,” says Bart Robbeets, general manager Industrial Gas Filtration, Donaldson. “Filtration technology plays an important role in this, but preventing pressure losses is a continuous task and an effective energy-reducing tool – not just for Donaldson, but for all our customers worldwide. Our local engineers are eager to get out on the road and help UK customers optimise and update their compressed air systems and boost their bottom line. This will result in a more efficient system, bringing substantial savings in energy and overall financial costs. Ultimately, our commitment lies in serving our customers and contributing to the reduction of the Total Cost of Ownership. Last but not least, advancing filtration for a cleaner world is what we do at Donaldson.”
Donaldson Company
www.donaldson.com
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