Energetica India Magazine October-November 2021

ENERGY EFFICIENCY 6 Tips to Reduce Compressed Air Energy Costs despite Production Demand 56 energetica INDIA- Oct-Nov_2021 Everything in our lives requires a regu- lar check-up, and in most cases timely replacement. This safeguards proper functionality and most importantly, re- sponsible for the better performance. It is no different in the case of a produc- tion facility, automotive manufacturing plants, Agriculture industry, refinery, food manufacturing plant, or any other place that requires their systems and equipment to work and perform its best. Uptime and production output are criti- cal elements in every industry. Same applies to Air compressors in a fa- cility or production plant, as it is a vital component just like other utilities. The compressor system is no different from the circumstances mentioned above. The tools, controls, valves, produc- tion equipment, etc. that require com- pressed air from the system all depend on its condition and production output. If the machine runs without being mon- itored, it might not be able to fulfill the production demand. Also, Compressed air accounts for a fair amount of total energy costs for indus- trial manufacturers - typically about 12% and maybe as high as 40% in some facil- ities considering it is an area which could have a big impact on the compressors. If the compressor has been used for a long period of time and might not giving desired output any longer, it means you need to get it replaced or find solutions to increase the output. 1. Reduce unloaded running hours Air demand in an industrial compressed air system typically oscillates. Using these patterns to reduce unloaded run- ning hours is a first step to enhancing energy efficiency. Compressor control - lers offer user-friendly ways to reduce unloaded running hours. If you have multiple compressors, then they should have been setup to do this automatically. But if there is no central controller, then the compressor pressure bands should have been set up in a cascade method, and the on-board controllers will stop the machines if they are not needed when the compressed air target pressure is achieved. If compressors are left running unload- ed after working hours, they still use as much as 25% of the energy consumed at full load. What’s more, if there are leaks in the system, the compressors may switch to loaded running occasionally, consuming even more energy. The shorter the production time, the more you can save by switching off com- pressors instead of letting them run un- loaded. If production is reduced but not stopped, a possibility would be to isolate areas of the factory that are not currently being used. The compressors may switch to loaded running occasionally, consuming even more energy. Alternatively, consider us- ing a Variable Speed Drive compressor which matches your compressed air with your factory air demand. 2. Eliminate air leaks Leakages are the biggest source of energy waste in older compressed air systems, with a leakage point as small as 3mm costing an estimated INR 4667/ Conrad Latham GM, Compressor Technique, Atlas Copco Compressed air accounts for a fair amount of total energy costs for industrial manufacturers - typically about 12% and maybe as high as 40% in some facilities considering it is an area which could have a big impact on the com- pressors.