How to save electricity (=money) with a compressed air system?
Use variable speed drive (VSD) compressors. Compressors with frequency converters adjust the motor speed according to the actual compressed air demand.
Advantages:
– 30-50% reduction in energy consumption
– Fewer load/idle cycles
– More stable pressure and less wear
Suitable for systems where compressed air consumption varies. The best results are achieved when combining a VSD and a fixed speed compressor.
Choose a compressor of the appropriate size.
– Oversized compressors operate inefficiently. Use consumption data to select the correct size.
Use smart control systems and air tanks.
– Properly sized compressed air tanks help smooth out peak loads
– Sequencing control optimizes the operation of multiple compressors more efficiently
Reduce system pressure.
– Every 1 bar pressure reduction results in approximately 7% energy savings.
– Keep system pressure as low as possible while maintaining reliability.
Repair air leaks in the plumbing.
20-30% of the compressed air produced can be lost due to leaks. Use ultrasonic leak detectors:
– Hoses
– Fittings
– To check valves
For example, a 3 mm hole at 7 bar pressure can cause significant costs per year. Create a leak management program.
Avoid unnecessary use of compressed air – compressed air is an expensive energy source.
Don’t use this:
– For cleaning dust
– For cooling
– For ventilation
Use a blower or fan instead.
Reuse the compressor’s heat – install a heat exchanger or add heat recovery to the compressor’s ventilation system.
Up to 90% of the compressor’s input energy is converted into heat. It can be used:
– For preheating industrial water
– For heating production facilities
– For process heat
Savings: up to 70-90%. Payback period less than 2 years.
Summary
The most important energy saving measures.
Compressors with frequency converter – potential savings of 30-50%
Heat recovery – potential savings of 70-90%
Leak elimination – potential savings of 20-30%
Pressure reduction – potential savings of 7% for every bar