Definitive Guide

Atlas Copco's new definitive guide to compressed air energy savings
July 14th 2006

Energy consumption represents around 80% of the total lifecycle costs of a standard compressor, but of the electricity consumed in the UK for generating compressed air 30% is wasted

Atlas Copco's new free Definitive Guide To Compressed Air Energy Savings CD offers eight ways to help compressed air operators to measure, control and reduce these ever-rising energy costs and to maximise energy efficiency. This is a synopsis of the CD presentation:

AIR AUDITS

The CD details Atlas Copco's AIRScan air audit that monitors usage patterns over a typical shift period to ensure that compressed air systems operate at maximum efficiency. The delivered flow of air can be checked and any leaks can be analysed - air leakage is recognised as being an area where up to 20% of energy is wasted.

COMPRESSOR SIZING

It is good practice to size systems to cope with peaks and troughs in current and expected air demand. Multiples of smaller machines can be more efficient than single large machines during lower production cycles. Dedicated compressors for particular processes are an option for times when the main demand is not required.

VARIABLE SPEED DRIVE COMPRESSORS

The CD explains that a typical Variable Speed Drive compressor can save up to 35% of compressor energy. Atlas Copco offers by far the broadest range of VSD stationary compressors on the market, with 24 model ranges from 7kW to 900kW, including oil free versions and full feature, WorkPlace models, with integrated dryer air and condensate treatment equipment.

AIR MANAGEMENT SYSTEMS

The CD introduces AIROptimizer, Atlas Copco's economic and reliable compressor system management designed to optimise the total system for minimal pressure band, maximum energy savings and easy to schedule maintenance. Intelligent control of multiple compressor installations reduces power costs by an average of 10%.

ENERGY RECOVERY

Most of the electrical power used by a screw compressor is transformed into heat. 94% of the heat dissipates into the cooling medium (which can be air or water). 4% remains in the compressed air and 2% is radiated into ambient surroundings. The available heat from a water-cooled oil-injected compressor can be recovered as hot water that can be used on site to reduce energy costs.

AIR TREATMENT

A 100-kilowatt compressor that draws in air at 20°C, and with 60% relative humidity, will decant approximately 85 litres of water during an 8-hour shift.

Energy savings can be made with today's ultra-efficient air dryers. Atlas Copco's MD adsorption dryer uses heat from the compression process to regenerate its rotor. 100% of the compressed air is delivered, and no electrical heater or purge air is involved.

LEAK DETECTION & CONTROL

Eliminating energy loss through leakage is the most important cost saving that can be made. Around 20% of compressed air is wasted in this way - £2.50 per hour based on a typical 250kW compressor at £0.05p/kWH. By repairing the leaks, energy consumption will be reduced and bring about immediate financial savings.

PREVENTATIVE MAINTENANCE

Regular compressor maintenance not only keeps production facilities operating at top efficiency, it is also an opportunity to reduce running costs. Around 80% of the lifetime costs of a compressor is for electricity, whereas servicing cost is marginal by comparison, as little as 10%.

A Freephone call to 0800 181 085 is all that is needed to have the new CD dropping into your mailbox

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