New Year. New Compressed Air Resolutions.

1. Review your existing compressed air system
   When was the last time you reviewed the performance of your compressed air system? From fluctuations in compressed air demand which may be caused by changing work patterns to ageing compressed air technologies, by reviewing your existing compressed air system you could unearth a number of energy saving opportunities and, many existing compressed air systems hide an energy savings potential of 30% or more!
   
   The first step may be to invite an experienced compressed air specialist to perform a simple walkthrough of your site. This alone may allow them to highlight to you a number of ways in which you could reduce your associated energy costs. Alternatively, consider undergoing a comprehensive compressed air demand analysis. As part of a compressed air demand analysis, meaningful and accurate data is gathered regarding your compressed air system's performance. This can then be used to identify what changes may be required within your compressed air system to make it the most efficient and economical in meeting your requirements.
   
   
2. Implement a leak detection program
   Unfortunately compressed air leaks will occur to some degree in every compressed air system. In fact, in a typical compressed air system they can waste up to 50% of the compressed air produced. Based on a compressor running 24/7 and a power cost of 15 cent/kW/hr, one 2 mm diameter leak could cost your business over $2,000 per annum. Imagine the overall cost of only a few leaks!
   
   The good news is that you can significantly reduce the impact of compressed air leaks by implementing a leak detection program and you can start the leak detection process with a very basic in-house assessment.
   
   For a more comprehensive solution, an ultrasonic leak detector (USLD) can be employed. With the correct training a member of your team could even perform this task. Alternatively, you could speak to your compressed air service provider about including regular leak detection into your scheduled maintenance program.
   
   
3. Optimise compressor performance to meet actual demand
   Fluctuations in shift patterns and production can both impact your demand for compressed air and, producing more compressed air than required is a costly exercise. It therefore pays to optimise compressor performance to meet actual demand.
   
   Compressed air systems typically comprise multiple compressors of similar or various sizes. As effective control is essential to ensure efficient system operation, where you operate multiple compressors, it is recommended that a master controller is implemented in order to coordinate the operation of individual machines.
   
   With a master controller, compressed air production can be precisely matched to suit actual compressed air demand. This ensures maximum energy and cost efficiency at all times. It is well worth investigating implementing a compressed air management system when you operate multiple compressors. Sophisticated solutions, such as the Sigma Air Manager 2 with 3-D advanced control, will analyse all operating data on an ongoing basis, simulate alternative actions and calculate the perfect compressor combination for unprecedented energy efficiency.
   
   
4. Consider the benefits of heat recovery
   100% of the electrical energy input to a compressor is turned into heat. The action of compression charges the air in the compressor with potential energy. This energy is given up at the point of use by the compressed air expanding and drawing heat from the surroundings. The total proportion of input energy available as heat is up to a startling 96%. The simplest and most direct method of recovering the heat generated in a fluid-/oil-cooled rotary screw compressor is by using the heat from the compressor system's warmed cooling air. This heated air can be ducted away to be used for space heating of warehouses and workshops or for other applications such as drying, heat curtains and pre-heating combustion air.
   
   Another application for heat recovery is to generate hot water. This could be used for a number of applications such as; heating, production or commercial cleaning purposes. Whilst heat recovery may often be overlooked in countries with warmer climates, there are clearly still a number of ways recovered heat could be used and, in the right application, heat recovery may offer significant additional energy costs savings potential. 
   
   
5. Follow the manufacturers prescribed maintenance schedule
   Investing in energy efficient compressed air solutions is only part of the story! To ensure your compressed air equipment operates at its optimum at all times, it is important to follow the manufacturer's prescribed maintenance schedule. There are a number of checks which should be completed, and consumables which should be changed by a qualified Service Technician at prescribed maintenance visits which are key to the ongoing efficiency of your compressed air equipment. And, as they say, prevention is better than a cure!

Take the first steps on the path to an energy-saving compressed air station with a free energy savings assessment from Kaeser Compressors Australia. Learn more here and enquire about this service.

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