Compressed Air Efficiency – How It Benefits Business

It is estimated that typically plants can waste up to 30 percent of their generated compressed air and that cost is substantial.  Considering the average cost to generate compressed air here in the Midwest is .25 cents per 1,000 Standard Cubic Feet, that translates into .075 cents for every .25 cents spent!  Compounded with the fact that energy costs have doubled in the last five years, it couldn’t be a better time to make your air compressor system more efficient.

efficiencylab

The following steps will help you save air and in turn save money.

  1. Measure the air consumption to find sources that use a lot of compressed air.

Knowing where you stand with your compressed air demand is important to be able to quantify the savings once you begin to implement a compressed air optimization program. Placing a value upon your compressed air consumption will also allow you to place a value on its costs and the savings you will reap once you start to reduce your consumption. (EXAIR’s Digital Flow Meter)

9093ZG-DG

  1. Find and fix the leaks in your compressed air system.

Not fixing your compressed air system leaks can cause your system pressure to fluctuate and affect your equipment negatively. It may cause you to run a larger compressor than necessary for your compressed air needs and raise your total costs. Or it could cause your cycle and run times to increase which leads to increased maintenance to the entire system. (EXAIR’s Ultrasonic Leak Detector)

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  1. Upgrade your blow off, cooling and drying operations using engineered compressed air products.

Your ordinary nozzle with a through hole and a cross drilled hole can be an easy choice based upon price, but if you do not consider the operating cost you do not really know how much it is costing you. An Engineered Air Nozzle will pay for itself and lower operating costs quickly. Engineered Air Nozzles are the future of compressed air efficiency and are made to replace ordinary nozzles, homemade nozzles and open line blow offs. Engineered Nozzles reduce air consumption and noise levels; ordinary nozzles cannot compete. Engineered Nozzles maintain safety features and can qualify for an energy savings rebate from a local utility; ordinary nozzles fall short. Open blow off or homemade blow off applications typically violate OSHA safety standards; Engineered Nozzles do not.  (EXAIR’s Air Nozzles)

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EXAIR Nozzles
  1. Turn off the compressed air when it is not in use.

Automated solutions add solenoid valves and run them from your machine controls. If the machine is off, or the conveyor has stopped – close the solenoid valve and save the air.  And blow off applications can benefit from any space in between parts by turning the air off during the gaps with the aid of a sensor and solenoid. (EXAIR’s automated  Electronic Flow Control)

 

  1. Use intermediate storage of compressed air near the point of use.

Also known as secondary receivers, intermediate air storage is especially effective when a system has shifting demands or large volume use in a specific area. Intermediate storage is the buffer between a large demand event and the output of your compressor. The buffer created by intermediate storage (secondary receiver) prevents pressure fluctuations which may impact other end use operations and affect your end product quality. (EXAIR’s Receiver Tanks)

  1. Control the air pressure at the point of use to minimize air consumption.

This is a very simple and easy process, all it requires is a pressure regulator. Installing a pressure regulator at all of your point of use applications will allow you to lower the pressure of these applications to the lowest pressure possible for success. Lowering the pressure of the application also lowers the air consumption. And it naturally follows that lower air consumption equals energy savings. (EXAIR’s Pressure Regulators)

By increasing your awareness of the health of your air compressor system and implementing a PM program you can significantly reduce your costs from wasted energy and avoid costly down time from an out of service air compressor.

If you would like to discuss improving your compressed air efficiency or any of EXAIR’s engineered solutions, I would enjoy hearing from you…give me a call.

Jordan Shouse
Application Engineer
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Video Blog: EXAIR’s Efficiency Lab

If you’d like to know how efficient (or not,) quiet (or not,) and effective (or not) your current compressed air devices are, the EXAIR Efficiency Lab can help.  For more details, we hope you’ll enjoy this short video.

If you’d like to talk about getting the most out of your compressed air system, we’d love to hear from you.

Russ Bowman
Application Engineer
EXAIR Corporation
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Business Benefits Of Compressed Air Efficiency

The primary business benefits of an efficient air compressor system are reduced operational costs, reduced maintenance and increased up-time.  With that being said, is your compressed air system costing you more than you think it should?  Are you having failures, pressure drops, inadequate volume and/or pressure?  You might think from these issues that your system has seen better days and is ready to be replaced.  However, it is possible that your existing tried and true compressor system has more life left in it than you think and with a few simple steps you could have it performing like a champ again!

It is estimated that typically plants can waste up to 30 percent of their generated compressed air and that cost is substantial.  Considering the average cost to generate compressed air is .25 cents per 1000 SCFM, that translates into .075 cents for every .25 cents spent!  Considering that energy costs have doubled in the last five years, it couldn’t be more timely to make your air compressor system more efficient.

So just where is all this waste occurring?  The largest source of compressed air energy waste is from unused or leaked compressed air and that is followed by line pressure drops, over pressurization and inadequate maintenance of the compressor.

So how can you identify this issues in your system?

1). Finding leaks can be accomplished by several methods such as soapy water applied to a suspected joint or connection or the EXAIR Ultrasonic Leak Detector.   It is a high quality instrument that can locate costly leaks in your compressed air system.  When a leak is present and audible tone can be heard in the supplied headphones and the LED display will light.  This testing can be done up to 20′ away so need to get on a ladder!

Leak Detector

2). Pressure drop is caused by is caused by the friction of the compressed air flowing against the inside of the pipe and through valves, tees, elbows and other components that make up a complete compressed air piping system.  If the piping system is to small, the flow (volume) will not be sufficient and the devices will not operate properly.  The volumetric demand would need to be added up to determine if the piping is of sufficient diameter to flow the required volume.  EXAIR’s Digital Flow Meter is an easy way to monitor compressed air consumption and waste.  The digital display shows the exact amount of compressed air being used, making it easy to identify piping that may be undersized.  Installing one on every major leg of your air distribution system to constantly monitor and benchmark compressed air usage is a fast and efficient way to see what your volume through that distribution leg is.

Flow Meter

3). Over pressurization is also an issue, as the pressure is raised to account for high demand periods, system leaks and pressure drops. Unfortunately operating at higher pressures can require as much as 25 percent more compressor capacity than needed, generating wasted air which is called artificial demand.

You can reduce the leakage rate by running the compressor at lower pressures. If you’re short on air, don’t turn up the pressure. Run your compressor at no higher pressure than what you process requires. To relieve peak demands on your system consider the EXAIR Receiver Tank.  It store’s compressed air during low usage times and releases it when the demand is increased without working your air compressor system harder.

receiver_tank

4). Finally, a preventative maintenance (PM) program will need to be implemented to keep the air compressor system running properly.  Two items that are often neglected are the drive belts and filters.  Loose belts can reduce compressor efficiency and dirty filters allow dirt to get through the system and cause pressure drops.  EXAIR has replacement elements for our line of filter separators to keep you air clean and line pressure down.

By increasing your awareness of the health of your air compressor system and implementing a PM program you can significantly reduce your costs from wasted energy and avoid costly down time from an out of service air compressor.

If you would like to discuss improving your compressed air efficiency or any of EXAIR’s engineered solutions, I would enjoy hearing from you…give me a call.

Steve Harrison
Application Engineer
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Video Blog: EXAIR Efficiency Lab

The video below is a brief introduction to the EXAIR Efficiency Lab, a free service provided by EXAIR for customers within the USA and Canada.

If you have a single point blowoff that does not have an engineered nozzle, or if you have a wider format blowoff, manifold or home-made drilled pipe, contact an Application Engineer with EXAIR and let us help you to reduce your energy waste. Following are some examples of product where we have helped to save some serious air and reduced noise levels which heightens employee comfort.

Non-engineered blowoffs

Drilled and soldered copper pipe.

Custom manufactured inefficient pipe blowoff

 

The EXAIR Efficiency Lab

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF