COMPRESSED AIR
SAVING ENERGY AND PROTECTING THE ENVIRONMENT WITH THE RIGHT COMPRESSED AIR SOLUTION
W
ith Europe experiencing soaring energy prices, and compressed air accountable for between 12 to as much as 40 per cent of all the industrial energy consumed1, many businesses are considering what steps they can take to minimise costs and improve the efficiency of their operations. Now is an opportune moment for energy-intensive organisations to take advantage of heat recovery, oil- free technology and digital analytics, says one of the industrial compressed air leaders, CompAir. In the first quarter of 2022, short-term gas
prices on the largest European exchange were five times higher than their 2021 average2, and future markets are pricing European gas at up to three times its 2021 levels for at least the next three years. However, CompAir is advising compressed air users that action can be taken now to help protect their investments for the future.
Here are some top tips that CompAir recommends, with advice on the company’s latest compressed air technologies, to help lower energy costs and optimise efficiency levels.
OPT FOR OIL-FREE SCREW COMPRESSORS
While most production-sensitive environments, such as those in the food and beverage or pharmaceutical sectors, will opt for an oil-free compressor, many other businesses would benefit from the efficiencies that an oil-free model can deliver. In many cases, whole life costs are reduced, with businesses able to save on the cost of oil replacement, and there’s no requirement for additional products such as oil separators. CompAir offers a wide range of oil-free
compressor technologies, including screw and piston machines. Its advanced Ultima compressor operates completely oil-free, with the cooling of components achieved via a closed water circuit. Each airend is driven individually by a variable speed, permanent magnet synchronous motor,
38 OCTOBER 2022 | FACTORY&HANDLINGSOLUTIONS
offering exceptional levels of efficiency versus traditional oil-free technology.
TAKE ADVANTAGE OF THE LATEST OIL-LUBRICATED SCREW COMPRESSOR TECHNOLOGY However, for those seeking an upgrade to an oil- lubricated system plus air treatment, the latest oil-lubricated technologies have been developed to optimise sustainability throughout the compressor’s lifecycle. CompAir’s FourCore range combines best-in-class compressed air efficiency with a small footprint and sustainable design for eco-conscious businesses.
For example, when carbon emissions from a new 160 kW FourCore model are compared with a traditional compressor, running for 8,000 hours a year, the FourCore system reduces the equivalent greenhouse gas emissions of 32 passenger cars, or 371,800 miles driven by a passenger car, over the course of one year. This is the same amount of carbon sequestered by 181 acres of forest. Furthermore, when compared with a
conventional two-stage compressor, the new 200 kW model uses 22 per cent less materials and can help cut waste by up to 19 per cent. And when compared with previous single-stage
compressors in this size range from CompAir, the new models are up to 8 per cent more efficient, offering a best-in-class oil-lubricated solution for decision makers.
TREAT AIR CORRECTLY Modern production systems and processes demand compressed air of ever-increasing purity. The proper specification of downstream equipment will not only further improve the quality and efficiency of a compressed air system but reduce its environmental impact too.
CompAir offers a wide range of compressed
air treatment solutions including filtration, refrigeration and absorption dryers and condensate management systems. High-quality consumables, such as filter elements with a long service life, ensure low component wear and consistently low differential pressure.
HEAT RECOVERY Meanwhile, taking advantage of measures such as heat recovery represents a considerable opportunity to lower energy costs, by recycling excess heat and using it to a site’s advantage. With typically only 10 per cent of the electrical energy input being converted into compressed air, the remaining 90 per cent is generally wasted as heat. By fitting a heat recovery unit to a compressor, the system can ‘recapture’ energy lost during the compression process and use it for other useful purposes. For example, it can supplement the electricity, gas or oil needed to generate hot water for washrooms or process water. Alternatively, it can be transferred as direct warm air into a workspace or facility.
CompAir offers multiple turnkey heat- recovery solutions for its oil-free and oil- lubricated screw compressors, both factory fitted and retrofittable. This allows for easy ‘plug-and-play’ installation and an immediate realisation of energy and cost savings.
DRIVE IMPROVEMENTS WITH DIGITAL INSIGHTS
The Internet of Things and data analytics can help operators to understand how efficiently a compressor is running, and whether any improvements can be made. These insights will not only help highlight any potential issues now, but also enable operators to forecast any
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