Compressors: 5 tips for cost-saving compressed air generation
The generation of compressed air costs a lot of energy and is often one of the biggest cost drivers in companies. Measures to reduce the energy consumption of compressors are therefore one of the best ways to keep total operating costs down. 5 tips for operators who want to optimize their compressed air system.
When energy disappears into thin air, it is not always annoying, but in certain cases even intentional: namely when it comes to compressed air. Compressors for industry perform a variety of tasks. They are used to drive pneumatic production systems, to operate lathe chucks, for parts cleaning or to transport components during production. However, the wide range of applications is also reflected in the energy requirements. Around ten percent of electricity consumption in the European Union is used to generate compressed air. High consumption and rising energy costs are a convincing argument for operators to examine their compressed air systems for optimization potential.
Whether blue or yellow, grey or any other color: Regardless of the manufacturer, electricity consumption accounts for over 80 percent of the total life cycle costs of a compressor. Reducing energy consumption is therefore at the heart of most cost-cutting measures. Here are five tips that offer particularly high potential.
1. speed control
Speed control or frequency control makes it possible to adjust the speed of the compressor as required. Instead of running at a constant speed at all times, the compressor adjusts its output to the actual demand. The compressor only works as much as is necessary, which significantly reduces energy consumption. By avoiding unnecessary energy consumption, operators can significantly reduce their operating costs. This also extends the service life of the appliances.
Practical examples: Compressors with speed-controlled drive from CompAir, speed-controlled units from AERZEN
2. leakage and pressure loss-free pipelines
Leaks and pressure losses in the piping systems of compressed air systems lead to considerable energy losses because the compressor has to work harder to compensate for the pressure drop. Regular inspection and maintenance of the piping and the use of high-quality materials and seals can prevent leaks and minimize pressure loss. This ensures that all the compressed air produced is used efficiently, reducing energy costs and the need for additional compression work.
Practical examples: Leak detection using ultrasonic measurement technology from KAESER, Atlas Copco AIRScan
3. heat recovery
Compressed air is not the only thing that compressors generate. A considerable amount of waste heat is also generated during their operation. By using heat recovery systems, it can be harnessed, for example to heat buildings or process water. This saves operators energy, as fewer external energy sources are required for these purposes. Companies can reduce their energy costs and make a contribution to sustainability at the same time.
Practical examples: Heat recovery with compressors from Atlas Copco, BOGE duotherm
4. digitization
Digitalization has found its way into industry and is not stopping at compressed air technology. It includes the use of modern sensors, data analysis and control technologies to monitor and optimize compressor operation. Real-time monitoring allows operating parameters to be continuously monitored and adjusted to ensure optimum efficiency. Early warnings of potential problems enable proactive maintenance measures that minimize downtime and extend the service life of the systems. This reduces maintenance costs and makes operation more efficient overall.
Practical examples: Compressed air 4.0 from BOGE KOMPRESSOREN, ALMiG COMPASS
5. system efficiency
A holistic view of the entire compressed air system – including not only compressors but also pipelines and consumers – makes it possible to optimize system efficiency. Intelligent systems can automatically determine the most efficient operating point and make adjustments to minimize energy consumption and costs. This also includes the integration of energy management systems, which enable a comprehensive analysis and optimization of energy use. By increasing system efficiency, the energy requirements of the entire system can be lowered, thereby reducing operating costs.
Practical examples: System intelligence as a holistic approach from AERZEN, KAESER SIGMA CONTROL 2
The bottom line is that a compressed air system that is optimized in as many respects as possible will still be one of the major consumers in operation. What is certain, however, is that each individual measure can offer great potential for reducing consumption and costs. Sample calculations indicate a 30 percent reduction in consumption for speed-controlled operation, for example. Depending on compressed air requirements, operators can save over 1,000 euros a year by reducing energy consumption by just 1 percent – good reasons to take a closer look at the compressed air system.
