Are you paying too much?
Are you paying too much? Here are some tips to help you reduce your running costs by making your compressor installation more energy efficient.
Eliminate air leaks.
Probably the biggest source of wasted energy in new and old compressed air systems is air leaks. Often, they occur in places that are difficult to see or inspect. Did you know that by fixing small leaks/hole could save you £1,000’s per year on your energy bill? Bet you would enjoy those savings? Air4UGroup can assist by carrying out onsite surveys to help you better understand the operational savings you could achieve.
Reduce system pressure.
For most compressor systems if you can reduce pressure by just 1 bar (14.5 psi) this would equate to a 6% saving in electricity consumption. On a lot of compressors this can be achieved very easily by some simple changes in the control parameters, the operating mode and pressure settings of the compressor. They can be adjusted until the optimal cut in pressure is reached, without affecting pressure.
Ensure the correct size of compressor is installed.
Choosing the wrong size air compressor for your facility can lead to problems with production, as well as increased costs due to wasted energy. It could also lead to increased maintenance requirements and poor air quality. When choosing the right type of compressor, you should ask yourself these questions:
- How much air does my factory/workshop need?
- What is the minimum pressure needed at point of use?
- Do you need clean/dry air to a specific quality?
- Are there fluctuations in flow demand? (e.g., less machines running overnight)
- Do you have any expansion plans for your factory in the future?
If you have no idea of the answers to some of these questions, Air4u Group can carry out a Compressed Air Audit which is an effective way to identify your current energy use and to assess your compressed air needs. This is carried out by attaching a Data Logger to the compressor for a minimum of 7-14 days. It observes and records any usage over that period.
Results will provide information on your compressed air usage. Also, they can identify busy and quieter periods and if there are any leaks in the system.
This can help to provide information on the overall efficiency of the compressor. As a result of the logging, we can get a more accurate understanding how your system is set up.
Designing an efficient compressed air system.
When looking to design your compressed air system it is important to consider more than just the air that you need at point of use. You should consider what air treatment package will be needed to achieve the air quality that you may need. Typical system components can include, refrigerant and desiccant dryers, particulate filters, pipework, condensate management and more. Careful attention in the selection of these components can help to minimise pressure drops while still maintaining the required pressure and air quality. E.g. do you really need desiccant dry air (typically, 15% of the rated flow capacity of the desiccant dryer is consumed as purge air)?
To assist you with your compressed air system design, Air4U are happy to help you.
Heat generated can be turned into useful energy with heat recovery.
Heat Recovery offers significant savings and allows you to harness waste heat from air compressors. Without heat recovery solutions, the heat is lost into the atmosphere. The amount of electrical energy that can be recovered depends on the type and size of the compressor, but total system heat recovery could be up to 94% of the energy used to run your compressor. Even some simple ductwork can be used to direct the air into your factory to help warm the building or to vent the hot air outside in the summer.