COMPRESSED AIR OPTIMISATION

Saving Money on Compressed Air

Air compressors or blowers can be a major energy consumer in lots of production facilities.  Lack of proper commissioning, maintenance issues and air leaks can account for 40% of this load.

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Energy use can be in compressed air

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Saving in energy consumption

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Real-time visibility of saving opportunities

Is Compressed Air the Bottom Line?

THE CHALLENGE

You could be wasting 40% of your air

Depending on your industry compressed air could be up to 50% of your electrical consumption on site.  We have seen massive savings in plants that run high pressure machines but also considerable savings in plants that use low pressure machines, multiple pressure systems, blowers or nitrogen generation.

The following are some of the issues we have seen that cause excessive energy consumption on compressed air plants:

  • Not monitoring on air systems
  • No maintenance or incomplete maintenance on machines (particularly belts, filters and lubrication.
  • Plants running in manual or with no automation or with the automation switched off
  • Plants producing excessively high pressure for the required operations
  • Incorrect installation of equipment
  • Water in compressed air
  • Incorrectly installed or maintained air dryer systems.

In addition compressed air generates heat and  in most facilities this is blown to the atmosphere.  This heat can be recovered and used in process or HVAC systems.

THE SOLUTION

Turn data into action

Solution

Use your data.  Use existing data from your compressors and other data available to you including power or flow meters or add these measurements to your system.  Map this data so that you can evaluate performance and track how systems are performing versus our modeled performance for your machines.

  • Carry out leak surveys and use the baseline data to determine when you need to repeat it from your data.
  • Monitor air flow, air pressure, consumed electricity and track these over time.
  • Determine when maintenance is needed from your data.
  • Determine the efficiency of machines vs similar machines.
  • Determine the loads of your air system and how best to serve it with your available equipment.
  • Determine when and if your compressors are needed and switch them off when not required.
  • Determine the optimal machines to operate in different production scenarios.
  • Use waste heat to reduce electrical or fossil fuel consumption

The solution lets you:

Build Predictive Models

Get insights by building individual models of each of the major components i.e. the compressors and condensers.

Identify what drives overall plant energy consumption

A robust method of tracking energy consumption is to use statistical analysis tools.

Overlay live data onto models

Bring those models to life i.e. feed them with live pressure, temperature data from the plant and calculate dynamically and continuously the predicted plant performance – and compare it to the actual.

The Business Benefits

Real, measurable savings

Our solutions have been deployed countless times to deliver real measurable savings to customers

 

The solution gives you:

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Rapid Delivery

Our 12-week proof of value model delivers savings from day one

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Visibility

We give you greater visibiity of you operating plant than ever before

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30%+ energy savings

We deliver real savings through optimisations

Guaranteed and Insured

We don’t leave it to chance, we guarantee the outcomes