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COMPRESSED AIR
In most instances
compressed air is an essential resource and it is sometimes referred to as the
fourth utility after gas, electricity and water. There is a common misconception that air is free! Air is only free – until it is compressed, then it becomes 10
times more expensive than electricity and it is therefore often the most expensive commodity used in
processes. The cost and effects on
the environment are not readily observed so its impact is lost on the user. An action plan should be implemented to identify the cost
and potential savings in the system:-
- Estimate annual running costs
- e.g. size of motor (kW) x running
hours/day x days/annum x cost of electricity/kWh
- Set up a leak reporting and repair
system
- e.g. Anglian Compressors Limited can survey your system using the latest ultrasonic detection equipment. We would use tags to identify the leaks and produce a report detailing the
actual cost to your business. This
report will also contain recommendations as to how these leaks can be repaired.
- No load tests during non production
periods can be carried out to prove the total amount of leakage on the
system, this will enable you to identify the efficiency of your system.
- Ensure that zero-loss drains are
used instead of timed, float or manual drains. This is one of the quickest ways of
obtaining a pay-back.
- Check the maintenance program for your
system.
- e.g. regular maintenance is
essential to minimize energy use. The major cost of running an air compressor is energy. Over the life of the compressor capital
cost is 15%, maintenance is 10% and 75% is energy.
- Consider waste heat recovery.
- e.g. Can the waste heat from the
compression process be used elsewhere for heating or drying. About 80% of the energy used by the
compressor is rejected as waste heat
- Check controls
- e.g. The compressor should not be
left running when air is not needed. Anglian Compressors Limited can offer advice on various compressor
management systems that will ensure your system operates at the lowest
acceptable pressure, only run the most suitable compressor at any time
and shut the system down when it is not required.
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