Atlas Copco Compressor Technique, one of the leader industrial organizations in the world, puts an end to energy loss through its analyses on the compressed air systems, the top energy-consuming item in plants. Atlas Copco states that an average of 40 percent of energy consumed in our country is used industrially and emphasizes that system performance will be increased through improvements achieved by regular inspections of compressed air systems. The company has also introduced a 10-item roadmap for energy saving.
Through free-of-charge analyses performed for compressed air systems that are the main cause of high energy consumption in plants, Atlas Copco Compressor Technique continues to help saving energy in plants regardless of being its own product or not. Stating that each compressed air system must be inspected regularly to achieve energy efficiency, Atlas Copco Compressor Technique specialists point out that it is possible to prevent energy loss with a roadmap to be prepared in consequence of detailed analyses by evaluating the malfunctioning and improvable parts of the system on site. The Compressed Air System analysis made by Atlas Copco Compressor Technique includes the processes such as review of all system components, installation of measuring instruments, data analyses, and modeling of the potential improvements.
“Compressed air is accountable for highest energy consumption; focus on this for saving”
Stating that measurement is very important for saving, Erdem Enç, Oil-Free Air Department Product & Marketing Specialist in Atlas Copco Compressor Technique said, “Compressed air is one of the most energy consuming items in a plant. Therefore, analysis for saving must start here. Regular inspections make it possible to discover how much energy compressed air system consumes. The main purpose of the compressed air system inspection is to find out and improve the inefficient points. Through improvements made with the help of regular inspections, system performance may be enhanced, production quality and capacity may be improved, and life cycle of other equipments in the system may be extended. Each compressed air system must be inspected regularly, and malfunctioning and improvable parts must be reviewed.”
“Pay attention to these indications”
Sharing the situations that require inspection, Erdem Enç said, “We can summarize the factors to care regarding the savings in compressor rooms as follows: If the compressed air system fluctuates very frequently and unpredictably, if the electric bill rises or falls inexplicably, if the system needs repair more often than usual, and if the installation is suspected to have leakages, it is necessary to consult an expert and have the system inspected as soon as possible. Additionally, it is also important that a compressed air system improved recently or not inspected for more than a year is examined by an expert.”
10 Energy Saving Suggestions by Atlas Copco Compressor Technique
1- Stop the Compressor: The compressor must be set to be stopped when it is not used. After working hours, most of the compressors are not stopped. The compressor that stays idle all night, continues to consume 25% of the energy it consumes during a full-load operation. Around 20% may be saved by stopping the compressor when it is not used (at nights and weekends).
2- Find the Leaks: Air leaks cause a huge energy loss. Air leakage of a ¼ inch becomes equal to a small car price in a year. Therefore, all leaks in the system must be detected and repaired.
3- Prevent New Leaks: Dry and filtered compressed air prevents new leaks by stopping dust and waste accumulation in the pipes.
4– Decrease Pressure: The rate of pressure must not exceed the required level. Each 1 bar decrease in the pressure decreases energy consumption by 7%.
5- Examine Piping: Increasing the pipe diameter from 2 inches to 3 inches may decrease the pressure loss by up to 50%. Shortening the distance to be covered by the compressed air also decreases the pressure loss by 20-40%.
6- Replace Filters Regularly: In order to ensure air quality and preclude pressure loss, it is also necessary to replace compressor filters regularly.
7- Check Water Drains: The condensate discharge device that runs on a timer may have remained open. This means that compressed air is being wasted. Air leak is eliminated by replacing water discharge devices.
8- Recover Waste Heat: Compressor generates heat while it pressurizes air. A big part of that energy may be recovered and used to generate hot water and heat in workplace.
9- Select Correct Maintenance Plan: A maintenance plan that suits the compressor should be selected. Besides contributing to decrease in energy costs, regular maintenance of a compressor prevents malfunctions and production loss.
10- Shift to New Technologies: Brand-new compressor control modules or electric motors contribute to more efficient systems. Shifting to new technologies provides minimum 2% saving in energy consumption.
For Detailed Information: Eti Danışmanlık Ayşe Uluğkay. [email protected]. 0533 459 87 58