Compressed Air Efficiency
- Can I lower the operating and maintenance costs without increasing the downtime?
- Can I improve my operational productivity?
- How can I make my compressed air system more efficient?
Any business owner or manager using compressed air systems wrestles with these questions regularly. It's because a compressor's energy costs are generally several times higher than its purchase price over its lifetime.
So, any practice that cuts down on operating and maintenance costs adds to companies' bottom lines. And as sustainability takes center stage, the efficiency of compressed air systems has become even more critical.
Unfortunately, many companies are not even aware of the possible cost-efficiencies of their compressed air systems, let alone implementing the best practices for cost savings.
Our objective is to support clients with end-to-end solutions to optimize their capital & operational costs. This article will teach you how to save energy, time, and money by achieving compressed air efficiency. You will learn about reducing costs on both sides of the operations: Supply and demand.
How to Achieve Efficiency
Monitor and optimize your efficiency
Efficiency, the ratio between compressor output and kW input, is the key performance indicator of choice to optimize maintenance strategy and costs.
Let's be cool
Breathe cool, fresh, and clean air
A compressor converts 90% of its power into heat. So, the overall operations consume more energy when the compressor room heats up. On the other hand, a compressor uses less energy to compress cold air. For example, 3 °C cooler air results in a 1% energy saving.
Get the complete picture
Measure, monitor, and manage
VPVision monitors your entire compressed air system from the supply side to the demand side. You can also use them as a complete energy management system to sustain and improve the energy efficiencies you've already achieved.
Create a smooth ride
Reduce the pressure drop
A properly designed piping system allows air to flow smoothly, resulting in less pressure drop. Here's how to do it:
- Use angular feed-ins at the main header
- Avoid T-pieces and elbows as much as possible
- Keep the average velocity in the pipe as low as possible
- Use proper-sized filters and dryers
Do you want to achieve compressed air system efficiency at your supply side? Talk to our efficiency experts at +971 432 32 523 or email us at email@example.com
Relax and save
Reduce the pressure
Every pressure reduction gives an instant win of 7% on your energy consumption. You can also invest in pressure regulators per production area to reduce artificial demand.
Please don't overdo it
Be selective with air quality
If one sub-process needs an extra low dew point, place the adsorption drier at the entry point of that sub-process only
Close the loop
Measure the right ways
For ring networks and large compressed air systems with multiple receiver tanks, you need bi-directional flow meters to measure reverse flow
Boost your profits
Manage your leakage
In general, a compressed air installation has 20-40% leakage. VPVision can be used as a global leakage management system and helps you rank the leaks on savings potential. Invest in an ultrasound leak detector today to find the leaks.
Air isn't free just because it's there
Shut off sections or machines when not in use
A simple manual or motorized shut-off valve can save thousands of dollars. Ensure that you're not losing the air through leaks such as vacuum nozzles and air knives or machines blowing off in idle positions. Flow meters help determine where and when you lose money during standstills.
Do you want to achieve compressed air system efficiency at your demand side? Discuss your requirements at +971 432 32 523 or firstname.lastname@example.org
Think of alternative uses
Do you need a compressed air-powered tool at all? Electric tools can be a better choice for many areas in your plant.
At CHS Industrial, we understand how to reduce energy consumption while maximizing production. In addition to compressed-air system audits and consulting, we also provide solutions to root out operational inefficiencies and reduce energy consumption. Discuss your project requirements here