In the world of compressors, there are often significant and unutilized energy-saving possibilities including energy recovery, pressure
reduction, leakage reduction and optimization of operations through correct choice of a control and regulation system as well as the
choice of compressor size.We are going to take a look at some of the opportunities for minimizing the compressor’s operating costs.
The power requirement concept
When making calculations, it is important to apply the overall power requirement concept. All energy consumers that belong to a compressor
installation should be accounted for: for example, inlet filters, fans and pumps, dryers and separators. For comparisons between
different investment alternatives, the use of comparable values is particularly important. Therefore, the values must be stated in
accordance with internationally recognized standards and regulations, for example, as per ISO 1217 Ed.4 -2009.
The working pressure
The working pressure directly affects the power requirement. Higher pressure signifies higher energy consumption: on average 8% more power
for 1 bar higher pressure. Increasing the working pressure to compensate for a pressure drop always results in impaired operating
economy.
Despite this adverse economic effect, increasing compressor pressure is a commonly-used method for overcoming pressure drops caused by an
under dimensioned pipe system or clogged filters. In an installation fitted with several filters, especially if they have been
operational for a long period of time without being replaced, the pressure drop can be significantly higher and therefore very costly if
unattended for long periods of time.
In many installations, it is not possible to implement large pressure reductions, but the use of modern regulation equipment allows the
pressure to be realistically lowered by 0.5 bar. This represents a power savings of a few percent. This may seem to be insignificant,
but considering that the total efficiency of the installation is increased by an equivalent degree, the value of this pressure reduction
in terms of actual savings is more readily obvious.
Optimizing air consumption
optimizing air consumption can have a lot of benefits
By analyzing routines and the use of compressed air, solutions to provide a more balanced load on the compressed air system can be found.
The need for increased air flow production can thereby be avoided to reduce operating costs.
Unprofitable consumption, which usually is a consequence of leakage, worn equipment, processes that have not been properly configured or the
incorrect use of compressed air, is best rectified by increasing general awareness. Dividing the compressed air system into sections
that can be separated using shut-off valves can serve to reduce consumption during the night and over weekends. In most installations,
there is some degree of leakage, which represents a pure loss and must therefore be minimized. Frequently leakage can amount to 10-15%
of the produced compressed air flow. Leakage is also proportional to the working pressure, which is why one method of reducing leakage
is to repair leaking equipment, and thereby lowering the working pressure, for example, at night.
Lowering the pressure by only 0.3 bar reduces leakage by 4%. If the leakage in an installation of 100 m3/min is 12% and the pressure is
reduced by 0.3 bar, this represents a saving of approx. 3 kW.
Regulation method
Using a modern master control system, the compressor central plant can be run optimally for different operating situations while enhancing
safety and availability. Selecting the right regulation method encourages energy savings through lower system pressure and a better
degree of utilization, which is optimized for each machine in the installation. At the same time availability increases, thereby
reducing the risk of unplanned downtime. Also, central control allows programming for automatic pressure reduction in the entire system
during operation at night and on weekends.
As compressed air consumption is seldom constant, the compressor installation should have a flexible design, using a combination of
compressors with different capacities and speed controlled motors. Compressors may run with speed control and screw compressors are
particularly suited for this, as their flow rate and their power consumption are virtually proportional to their speed.
How does energy recovery work in compressors?
When using electricity, gas or oil for any form of heating within the production facilities or in the process, the possibility of fully or partly replacing
this energy with recovered waste energy from the compressor installation should be investigated. The decisive factors are the energy cost in €/ kWh,
the degree of utilization and the amount of additional investment necessary.
A well-planned investment in waste energy recovery often gives a payback time of only 1–3 years. Over 90% of the power supplied to the compressor can be
recovered in the form of highly valuable heat. The temperature level of the recovered energy determines the possible application areas and, therefore,
its value. The highest degree of efficiency is generally obtained from water-cooled installations, when the compressor installation's hot cooling water
outlet can be connected directly to a continuous heating demand, for example the existing heating boiler's return circuit.
Recovered waste energy can then be effectively utilized year round. Different compressor designs give different prerequisites. In some situations requiring
a large and peaking heat flow, long heat transport distances to the point of utilization, or a requirement that varies during the year, it may be interesting
to look at the possibilities of selling the recovered energy in the form of heat or cooling or electricity, etc.
Do you have an idea for our #expertcorner? Let
us know!
Who we are and how Ash Air can help your business!
Ash Air has been around in New Zealand since 1979, and we’ve grown into a nationwide company with international support and a
reputation for quality and reliability.We look after all things compressed air for your business!
Reciprocating, Screw, air compressors
Vacuum pumps
Nitrogen
An extensive line of air treatment components
Ash Air's range of Chicago Pneumatic, Alup, Pneumatech, and Quincy compressors are used extensively around the world in industries
ranging from oil and gas to food, automotive and farming, and we bring you these world class compressors here in the land of the long white
cloud.Our technicians are compressed air equipment experts and are dedicated to addressing customer needs. Supported by a 13 locations
nationwide, Ash Air offers one of the widest selections of compressed air equipment and parts available today in New Zealand.
Reliability and Efficiency
With Ash Air compressors, you can count on reliability and high performance for even the most demanding applications. We focus our
efforts on the following:
Air compressors come in many types, rotary screw, piston, scroll, reciprocating, some are oil-free and other air compressors require oil
lubrication. Like many businesses, an efficient air compressor is at the heart of their operations. So, which type of compressor should you
choose? What makes a compressor, like a rotary screw, unique? Here are some clear cut benefits of equipping your business with a rotary
screw compressor. Â
Read More…
In the world of compressors, there are often significant and unutilized energy-saving possibilities including energy recovery, pressure
reduction, leakage reduction and optimization of operations through correct choice of a control and regulation system as well as the choice
of compressor size.We are going to take a look at some of the opportunities for minimizing the compressor’s operating costs.Â
Read More…
Many installations that produce compressed air offer significant and frequently unutilized energy
saving possibilities in
the form of waste energy recovery. In large industries, energy costs can amount to 80% of the total cost of compressed
air production.
However, a lot of this energy can be recovered, which in turn will save you a lot of money.Â
Read More…
Liquid water in compressed-air systems can lead to rusted equipment and unresponsive controls. Anyone who uses compressed air will, at some
point, find liquid water in the air distribution system. This can be anything from a nuisance to a serious problem, depending on the
application. If water might corrode equipment or introduce bacteria, removing it is critical.Â
Read More…
Liquid water in compressed-air systems can lead to rusted equipment and unresponsive controls. Anyone who uses compressed air will, at some
point, find liquid water in the air distribution system. This can be anything from a nuisance to a serious problem, depending on the
application. If water might corrode equipment or introduce bacteria, removing it is critical.Â
Read More…
Whenever most people think about a compressor, they probably have a piston compressor in mind. You might already know there are two basic
principles of air compression. One of those is the principle of displacement compression. There are a lot of compressor types that classify
as a displacement compressor. The piston compressor is one of them, oil-lubricated or oil-free.Â
Read More…
Once you have the size and type of
compressor figured out, one last question remains, should I go with an oil lubricated or oil-free air compressor. To not overcomplicate the
answer, your choice should be based on the application and process that the compressed air will be utilized in.
Read More…
Like all compressor types, rotary screw models do require periodic maintenance. Thanks to the simplicity of the internal components,
maintenance is relatively easy on most rotary air compressors. As long as you stick to a rotary screw compressor maintenance schedule, you
will likely be rewarded with many, many years of optimal productivity from your machine.Â
Read More…
Did you know, the biggest part of the air we breathe is nitrogen? Everyone needs oxygen to survive, however air is made up of 78% nitrogen,
only 21% oxygen and tiny amounts of other gases. Although, the human body does not use this nitrogen, it is very helpful in various
industrial applications. There is an unlimited source of nitrogen readily available, allowing you to achieve needed purity at a fraction of
your current annual nitrogen cost.Â
Read More…
If you notice that your compressor is getting hot and bothered, there may be heating issues affecting your air compressors performance. Did
you know that an overheating compressor is top of the pops for being the most common cause of compressor failure.Â
Read More…
A rotary-screw compressor is an air compressor that uses a rotary-type positive-displacement mechanism, typically used replace piston
compressors where large volumes of high-pressure air are needed, either for large industrial applications or to operate high-power air
tools.Â
Read More…
Have a look around and what do you see? What are you thinking about? Your next holiday to Queenstown maybe? You might go snowboarding with
the kids or have some alone time at the Day Spa. Whatever holiday you choose, compressed air is involved in some way, without you even
realising it! Â
Read More…
There are crucial reasons why you should service and maintain your compressor regularly, with the most common issues being piston failure
caused by wear of components, increased friction, corrosion, reduced cooling, overheating bearings and components, clogging of air filters.Â
Read More…
Our passion for energy efficiency and cost saving derives from the concern for our children’s future. Analysing the efficiency of your
system is a brilliant way to start saving.
Read More…
Compressed air is all around us, from the air in a balloon to pumping up tires on your bicycle. In this article we will explain what
compressed air is and how it is created. Whether you know it or not, compressed air is involved in every aspect of our lives, from the
balloons at your birthday party to the air in the tires of our cars and bicycles. It was probably even used when making the phone, tablet or
computer you’re viewing this on.Â
Read More…
One of the biggest challenges is to correctly size your new air compressor. Similarly to everything else, new compressors available on the
market are more efficient and employ better technology, therefore you have to understand the application and usage to size the machine
correctly. Choosing the wrong air compressor for your facility can lead to problems with production and or increased costs due to wasted
energy.Â
Read More…
Once you have the size of the air compressor figured out, the
next thing to do is to decide on the type of compresor you will need for your application - piston, rotary screw compressor etc. Let us take
a look at two of the most popular options available. When choosing the right type of compressor, you should ask yourself the following
questions:
Read More…
​Which vacuum pump do I need? - this is one of the most frequent questions we receive and this is understandable, because there are number
of technologies which can provide the same vacuum level and pumping speed. Here is quick advice on how to choose the best vacuum pump for
your needs.Â
Read More…
You may be asking, why does my air compressor start, then stop? Allow us to take the guessing out of it. We understand your pain. We know
that a compressor problem can quickly result in hours (if not days) of production downtime and loss of revenue. When your compressor
continuously shuts off from on, we refer that as a short cycle. There are a few reasons that a short cycle may be happening with your
compressor.Â
Read More…
Air compressor leaks are very common in all applications, but can be very costly and difficult to find. On average, 20-30% of the compressed
air used in a manufacturing plant is wasted as leaked air. Finding and fixing these leaks can save your business thousands of wasted dollars
a year.Â
Read More…
When installing a compressed air system into a business, people often look to PVC piping as an option to build a piping system because it is
cheap, versatile and easy to install. However, using PVC pipe in any compressed air application is extremely dangerous and NOT recommended
by multiple associations and manufacturers.Â
Read More…
Changing the oil and oil filters on your compressor is one of the most common routine maintenance tasks to perform to keep your compressor
running efficiently. After you remove your old oil and oil filter, you may find yourself wondering, “Where do I dispose of these?”, or “Can I
just throw them in the trash?”. Because oil is toxic and a pollutant, disposing of your old oil and filters is not as simple as just tossing
them in the trash.Â
Read More…
