A recent survey has identified that faulty or inefficient air compressors are costing UK businesses over £100 million per year. Why is this and what steps can be taken to keep the costs down?
True Costs
Compressed air production accounts for 10% of all of the electricity consumed by indudtry in the UK. It’s used in businesses as diverse as aircraft manufacturing, electronic and engineering to name but a few. Although you might think that the cost of producing it is relatively low, you couldn’t be more wrong.
How much?
Over the ten-year average lifespan of a compressed air system, 75% of the total costs are attributable to the energy it uses. One of the main reasons for this is that most existing air compressors are fixed speed machines operating inefficiently at only 40% to 70%of their full load capacity.
Misuse and Leakage
As this lack of understanding continues to prevail, little, if anything, is being done to deal with wastage via leakage and miuses. It’s still quite common for operators to use compressed air to blow dust or shavings from machinery as it’s seen as the low-cost solution to the problem, when in fact the opposite is true.
Across British industry it’s estimated that leakage averages 30% of the total air produced. This means that some sites are losing as much as 75% of the total air generated. The detection and curing of leaks are vital activities: a single pin-hole leak can be responsible for an annual financial loss of £30; a number of leaks amounting to the equivalent of a match head can cost £300; whilst a major blow of only 3mm diameter will cost the organisation over £1000 per annum.
It doesn’t have to be this way
The Carbon Trust has produced a guide that provides practical advice on choosing an air compressor, maintenance, leak prevention and using compressed air appropriately. By following a series of simple measures you can make significant cuts in electricity consumption. The following savings can be achieved:
TIP 1. Implement a policy that spelss out what the acceptable uses for compressed air are.
TIP 2. Carry out regular maintenance checks to ensure that pressure is regularly measured, controls are working properly and the condensate collection system is functioning correctly.
TIP 3. Make sure that operators are always on the look out for leaks. Reducing air leaks is the single most important energy-saving measure.
TIP 4. Turn off compressed air-consuming equipment when it’s not required. Even when idling, compressors can consume between 20% and 70% of their full load power.
TIP 5. Check air quality and pressure dew point. It’s likely that only some processes need the air to be treated to a highly specified level.
The next step…
For a copy of the Carbon Trust’s guidance (EN 06.09.02B), visit http://environment.indicator.co.uk
Money and energy are being wasted because air compressor machinery isn’t being used properly or efficiently. You can address this by implementing a usage policy, and identifying and fixing leaks. Longer-term options include replacing machines with variable speed devices which use 30% less energy.
Taken from: Indicator 6th year – issue 9 February 2012
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