Energy Savings
Compressed air accounts for 10% to 30% of electricity consumption in industrial enterprises and therefore holds significant savings potential. Representing approximately 4-5% of global electricity consumption, compressed air systems play a critical role in production processes and are supplied through compressors.
Compressors are inherently inefficient. Approximately 85% of the consumed energy is lost as heat, while only 15% is converted into compressed air production. Moreover, about 75% of a compressor's total 10-year cost arises from energy consumption.
One of the most effective ways to achieve savings in compressed air systems is through leak detection efforts and the elimination of air leaks. Additionally, proper system design, recovery of compressor waste heat, and the use of compressors with frequency inverters significantly enhance energy efficiency.
Energy Efficiency Initiatives for
Compressed Air Compressors and Compressed Air Lines
Within the scope of compressor performance measurement (flow, pressure, temperature, energy consumption) activities, the flow rates of compressors are measured using compressed air flow meters. At the same time, the amount of energy consumed by compressors is measured, and their specific energy consumption is calculated. Thus, compressor efficiencies are analyzed based on specific energy consumption, enabling measures to be taken against energy losses.
| Compressor No. 1 | |
| Min Max Values | |
| Min Flow Rate | 10.59 m³/min |
| Max Flow Rate | 18.75 m³/min |
| Min Temperature | 36.05 °C |
| Max Temperature | 36.9 °C |
| Min Pressure | 6.43 bar |
| Max Pressure | 6.95 bar |
| Energy Consumption Per Hour | 114 kW |
| Specific Energy Consumption | 0.101333333 kW/m³ |
Proper pipe diameter in compressed air installations is important within the scope of energy efficiency initiatives. Pipe diameter suitability should be determined by measuring with flow meters on compressed air lines. Correct pipe diameter is crucial to minimize pressure drops in the lines. Pressure drops caused by undersized pipes result in significant energy losses.
Measuring the dew point and pressure drop of compressed air dryers is part of energy efficiency initiatives in compressed air systems. Failure to perform periodic maintenance on compressed air dryers over time leads to pressure loss due to desiccant deformation in chemical dryers and heat exchanger clogging in gas dryers. These pressure drops cause significant energy losses. Additionally, this situation results in an increase in the dew point value of the dryers and prevents the dryer from fully drying the air. Therefore, timely periodic maintenance is essential, and monitoring dryer pressure losses and dew point values through measurement is necessary.
Measuring the dew point and pressure drop of compressed air dryers is part of energy efficiency initiatives in compressed air systems. Failure to perform periodic maintenance on compressed air dryers over time leads to pressure loss due to desiccant deformation in chemical dryers and heat exchanger clogging in gas dryers. These pressure drops cause significant energy losses. Additionally, this situation results in an increase in the dew point value of the dryers and prevents the dryer from fully drying the air. Therefore, timely periodic maintenance is essential, and monitoring dryer pressure losses and dew point values through measurement is necessary.
Evaluating the capacity of compressed air dryers is also important in compressed air energy efficiency efforts. The dryer’s capacity can be determined by measuring flow rate, pressure, and temperature at the compressor outlet. When determining dryer capacity, calculations should not be based solely on flow rate. Pressure and temperature correction factors must also be considered to accurately determine dryer capacity. Incorrect determination of dryer capacity will increase the resulting pressure drop and will also fail to achieve the expected dew point value from the dryer.
Frequently Asked Questions
Get more information about energy savings.
To achieve energy savings, leak detection and repair work should be prioritized. Additionally, operating the system at the correct pressure level, preventing unnecessary pressure drops in the air line, and using energy-efficient equipment are also of great importance.
Leak rates in compressed air systems can typically reach levels of 20-30%. This leads to unnecessary energy consumption and increased operating costs. Regular inspection and repair of leaks ensure the system operates more efficiently.
For compressors to operate efficiently, they should not be run at unnecessarily high pressure, regular maintenance must be performed, and the capacity of air tanks and reservoirs should be properly determined. Additionally, using compressors with frequency inverters enables energy consumption to match variable air demand.
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