Energy Intelligence for Pumps and Compressors

Related Vendors

Lutz Pumpen GmbH

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Compressors and Pressurised Air: Where the Energy is Lost...

Industry uses compressed air similar to the way it uses electricity from a power socket. Compressed air is a very important source of energy in many production applications.

Around 62,000 compressed air systems are installed in Germany alone. Because compressed air is safe, reliable and easy to use, cost is a secondary consideration for many users. In some cases, a lot of money literally leaks off into thin air. Loss rates of 15 per cent are the rule rather than the exception, and losses can be as high as 70 per cent. All major manufacturers now offer a compressed air audit service to identify leaks, poorly dimensioned compressed air lines and mismatches between supply and demand.

Optimized Compressed Air Management Reduces Costs, Efforts and Maintenance: Compressed Air/Vacuum Technology — Requirements Dictate System Design

Energy Efficiency on Compressors – A Huge Potential

Maximising the energy efficiency of every single compressed air component is necessary, but even more is needed to optimise the overall system. With the exception of continuous flow production in the process industry, analysis reveals fluctuations in the demand profile. If that is the case, it can make sense to invest in variable speed compressors. A higher-level controller is recommended on larger systems, so that multiple compressors at a station can be operated in a coordinated fashion. For example, splitting the load between different size compressors can increase load response efficiency.

A central compressed air station has advantages, but extremely long compressed air lines can make distributed supply the better option. Service and maintenance are easier if the compressors are consolidated in one place. Compression generates heat, and a heat recovery system can further reduce energy costs. As much as 96 per cent of the energy that is supplied to a compressor can be reused as waste heat (e.g., for heating purposes).

Read also our Whitepaper on the Design and Troubleshooting of Compressor Systems with Dynamic Process Simulation

Compressed Air Contracting on the Increase

More and more companies are choosing the contracting option, which allows them to install a new, energy-efficient compressed air system without tying up capital. A compressed air profile (maximum, average and minimum consumption) should be created before the compressed air contracting model is agreed with the customer. It is important to understand the consumption dynamics, in other words the magnitude of the fluctuations in volume flow and pressure that occur in a minute/hour/day. What are the compressed air quality requirements? Does the customer operate one shift or multiple shifts?

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