6 Tips to reduce compressed air energy costs
If you have to reduce production at your manufacturing plant, you may welcome the chance to save on energy costs. Here you can find 6 tips to reduce compressed air energy costs whatever your production demands are.
Compressed air accounts for a fair chunk of total energy costs for industrial manufacturers - typically about 12% and maybe as high as 40% in some facilities, so it is an area which could have a big impact. Optimistic shows 6 tips aim to help you reduce your running costs at a difficult time:
1. Reduce unloaded running hours - The first step to optimising energy efficiency is by using these patterns to reduce unloaded running hours. Air demand in an industrial compressed air system typically fluctuates. If you have multiple compressors, then they should have been setup to do this automatically. If there's no central control, the compressor pressure bands should have been set up in a cascade method, and the on-board controllers will stop the machines if they are not needed when the compressed air target pressure is achieved. Leaving the compressor running unloaded after working hours they still use as much as 25% of the energy consumed at full load. And more, if there are leaks in the system, the compressors may switch to loaded running occasionally, consuming even more energy.
2. Eliminate air Leaks - Leakages are the biggest source of energy waste in older compressed air systems, with a leakage point as small as 3mm costing an estimated INR 4667/week in wasted energy. It is estimated that up to 20% of total compressed air consumption may be lost through leaks. we recommend taking the opportunity to detect the leaks in your system. For example, you could run your air compressor with no production to check for leaks. Fixing air leaks will start to save you money immediately, only if you work on site and have some spare time.
4. Turn compression heat into useful energy with heat recovery - Without energy recovery, the heat is lost into the atmosphere via the cooling system and radiation. The amount of electrical energy that can be recovered depends on the size of the compressor and the running hours, typical recoveries are between 70-94%. Recovering heat from compressed air reduces the need for purchasing energy, and this reduction results in lower operating costs and CO2 emissions, also reducing your carbon footprint.
Source: Atlas Copco