Inefficient Compressed Air Generation Could Be Increasing Your Overhead Costs
Spiralling Energy Costs now dictate the need to run your Compressed Air Systems to their maximum efficiency.
If you’re interested in how much wasted energy is costing your company its time to take advatage of our energy efficiency audit, contact us now for more information.
Reducing system pressure by 1 bar is the equivalent of a 7.5% reduction in consumed electrical power. In addition system leakage will be reduced by approximately 10%.
Carbon Trust surveys monitored by the Carbon Trust have shown leakage rates in excess of 20% of system capacity.
Compressed Air System Demand 250 CFM @ 7.5 Bar
System Power Demand 45Kw
Annual Production Hours 4,000
Average Kw/Hr Energy Cost 10p
RUNNING COST= 4,000 x 45 x 10 = £18,000
PRESSURE REDUCTION BY 1 BAR
7.5% x (4,000 x 45 x 10) = £1,350
Leakage Reduction 10% of 50 CFM = 0.9Kw x 4,000 X 10 = £360
TOTAL SAVING = £1,710
Compressed Air System Demand 1,000 CFM @ 7.5 Bar
System Power Demand 160Kw
Annual Production Hours 8,760
Average Kw/Hr Energy Cost 10p
RUNNING COST= 8,7600 x 160 x 10 = £140,160
PRESSURE REDUCTION BY 1 BAR
7.5% x (8.760 x 160 x 10) = £10,512
Leakage Reduction 10% of 200 CFM = 32Kw x 8,760 X 10 = £2,803
TOTAL SAVING = £13,315
Generating compressed air accounts for a high percentage of a production plant's electrical running costs. Unnecessary offloading, poor regulation and over pressurisation are the main causes of high running costs. Industrial Air Power can offer a free site audit to instantly identify areas where improvements and energy savings can be achieved. These include:
Energy Efficient Compressors
Nirvana Variable Speed Technology – HPM Motors coupled to a tried and tested airend package produce the most efficient variable speed compressor across the entire load range.
- Two Stage Technology – Higher output base load compressor with lower specific power greatly reduces electrical energy to generate compressed air.
- Nirvana Two Stage Variable Speed Technology – with the combination of the above, these compressors benefit from the lowest constant specific powers across the entire load range. Download Case Study.
A controller is designed to provide management of a multi machine compressor system under optimal pressure control and efficient utilisation. Download Brochure
Retrofitting an inverter to an existing compressor can help reduce unnecessary offloading achieving lower capital expenditure. Download Brochure
Industrial Air Power also provide the following services:-
Compressed air is energy. Leaking air lines, couplings and hoses are simply put, sources of energy waste. The majority of companies have a leakage rate of more than 20%. Apart from being completely unnecessary, it is expensive and contributes to your CO2 emissions. In an Industrial Air Power leakage management program your leakage level will be reduced to less than 5%. What does leakages presently cost your company?
Industrial Air Power will be pleased to discuss with you a 'Leak Management Program' where we will identify and tag leaks and present you with an in depth written report. This will highlight:
- Leakage Rate
- Leakage Waste Costs
- CO2 Emissions
- Percentage of repaired leaks
If you would like to discuss a Leak Survey of your current system, savings of 20% or more of your current electrical running costs are possible. For more information contact us today.
We recently carried out a Leak Survey at a production plant with an average compressed air usage of 1200cfm. Following the survey we identified leaks of more than 400cfm (30%) equating to savings of £56,000 per annum. Within weeks savings of almost £10,000 were achieved with a structured IAP Preventative Maintenance Plan.
Inefficient compressed air generation can cost your company unnecessary expense. Spiralling energy costs now dictate the need to run you compressed air system to its maximum efficiency. Optimising compressed air generation to suit individual requirements is absolutely essential in today’s competitive market.
Reducing system pressure by 1 bar is the equivalent of a 7.5% reduction in consumed electrical power. In addition system leakage will be reduced by approximately 10% reflecting the reduction in pressure.
Your company may be eligible for interest free funding for energy modifications.
Benefiting the environment and reducing energy costs
Production requires power, and power costs money. Consider that the average price for oil, natural gas and coal have all increased significantly in recent times and will likely continue to do so. These increases — as well as the global focus on preserving the environment — have driven many businesses to look into new ways to conserve energy.
The overwhelming majority of the energy used to run a compressor is converted into heat through the compression process and this heat is normally left to absorb into the cooling cycle. With up to 85% of recoverable energy potential from the heat of compression, an energy recovery system can significantly reduce total energy consumption.
The Ingersoll Rand Energy Recovery System (ERS) provides a cost-effective way to reduce your energy bills and benefit the environment by capturing this heat and putting it to work. The Ingersoll Rand ERS coolant-to-water heat exchanger utilises the thermal energy captured in the compressor coolant to heat water up to 70°C (160°F).
This hot water can be used in a variety of applications, including:
- Pre-heated boiler feed water
- Process water
- Tap water
- Space heating with hot water heaters
- Many other applications that call for warm or hot water
By supplementing your current water heating system with recovered heat, the Ingersoll Rand ERS allows you to significantly reduce your total energy consumption without the addition of any further losses and without compromising compressor reliability in any way.
Is old equipment making your business uncompetitive or simply costing a fortune in energy bills?
An interest free loan will give you the opportunity to both modernise your business and simultaenously reduce overheads with your loan repayments covered by the estimated energy savings. The loans are unsecured and interest free with no arrangement fees and a straight forward application process with loans repaid over a period of up to four years. The scheme is designed for energy savings to cover repayments - the loan will effectively pay for itself.
Who is eligible?
Your organisation must fulfil the following criteria:
- Private Sector
- Trading for at least 12 months
- Acceptable Credit Rating
- Based in the UK (England, Scotland and Wales)
- All small or medium enterprises (SME) or any business that do not qualify for participation in the Carbon Reduction Commitment (CRC).
The size of loan available and the repayment periods will be based on your projected CO2 savings, which will be assessed by the Carbon Trust. For full details of how a loan could work for you IAP can arrange a meeting with a local Carbon Trust Loans advisor.
For more information contact us today.