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.
Energy use can be in compressed air
Saving in energy consumption
Real-time visibility of saving opportunities
Is Compressed Air Compressing the Bottom Line?
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:
Incorrectly installed equipment and/or air dryer systems.
Lack of Monitoring
Plants running in manual or with the automation switched off, no monitoring on air systems, and plants producing excessively high pressure for the required operations.
No maintenance or incomplete maintenance on machines (particularly belts, filters and lubrication), and/or water in compressed air.
Turn data into action
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.