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Compressed air systems are common on most industrial sites as compressed air is a very practical, usable and safe form of energy.  Compressed air systems consume vast quantities of energy and are commonly incorrectly set to match site needs.  In addition, sites using large quantities of nitrogen usually have their own pressure swing absorption (PSA) generation systems that are fed with compressed air.

 

The end user of the compressed air often does not understand the cost of the air they use and lose.  The compressor motors are normally the largest motors on site, therefore any loading reduction will have substantial power savings.  

 

A typical compressed air system consists of compressors, receivers, filters, driers and distribution network. It is important to view the system as a whole and ensure it is set up correctly, free from leaks and producing air efficiently.  

 

How can Enerjon help you?

Enerjon has demonstrated significant system energy savings of up to 40% by performing the following work on and changes to compressed air systems:

  • Review the site compressed air requirements and compare to the current site compressed air system design and settings.
  • Check the performance of the major components in the compressed air system - compressors and driers.
  • Perform site air leak survey to develop improvement list.

 

Using data from the above survey work it is now possible to implement the following:

  • Working with end users, develop a list of areas and equipment to shutdown when not required.
  • Working with site engineering and approved contractors to work through and repair the identified site air leaks.
  • Working with the equipment service engineers, set the major components onto their most efficient setting to match site requirements.
  • Monitor the site reduction in compressor loading, produce reports highlighting the improvement progress and feedback to the workforce.
  • Set up regular improvement groups to discuss current and future changes, display the information and improve site awareness for energy reduction.
  • Develop a longer term improvement plan, this would capture the larger cost items such as variable drive compressors (VSDs), efficient driers and modern sequencer control.
  • Quantify heat recovery value, identify workable solutions, prepare projects and support commissioning to optimise.

Compressed Air Systems

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