- Understanding the Importance of Air Compressor Cost Saving
- Considering All Energy Consumers
- The Right Size
- Rotary Screw vs. Piston Compressors
- Optimizing Operations with Control and Regulation Systems
- Aftercoolers, filters, and dryers
- Life Cycle Cost Analysis
- Common Questions Related to Cost-Reducing Air Compressors
Since up to 80% of air compressor costs is made up of energy expenses, you'll want the most efficient set up. The first step for evaluating the right solution is to determine how much pressure and flow you'll need for your application.
In addition, it's important to pay attention to the overall humidity of your work environment, and pressure dew point (PDP) recommended for your industry. There are also other equipment and parts worth evaluating like aftercoolers, filters, and monitoring and control tools.
This brief guide aims to help you better understand what you'll encounter in relation to overall operational costs of an air compressor. Of course everyone's needs differ, and it's important to take this into account when determining the right solution for you.
Air compressors play a crucial role in many industrial processes, but they are also significant energy consumers. In fact, around ten percent of electricity consumption in the European Union is utilized for generating compressed air.
With energy costs on the rise, optimizing compressed air systems to save costs has become a priority for many operators. The majority of the life cycle costs of a compressor are attributed to electricity consumption, making energy efficiency a key focus for cost-saving measures.
Energy Recovery in Air Compressors
Energy recovery is one of the most effective ways to reduce operating costs in air compressors. During the compression process, a significant amount of heat is generated. This heat can be recovered and reused for various purposes, such as heating water or air, which can lead to substantial energy savings. Implementing energy recovery systems can help businesses reduce their overall energy consumption and lower their operating costs.
Pressure Reduction Strategies
The working pressure of an air compressor has a direct impact on its energy consumption. Higher working pressures result in higher energy usage, with an average of 8% more power required for every 1 bar increase in pressure.
While it may be tempting to increase pressure to combat issues like pressure drops, this can actually lead to decreased operating economy. Modern regulation equipment allows for realistic pressure reductions, leading to power savings and increased efficiency.
Leakage Reduction Techniques
Air leaks are a common issue in compressed air systems and can lead to significant energy losses. Identifying and fixing leaks is crucial for reducing operating costs. Regularly inspecting the system for leaks and using technologies such as ultrasonic leak detectors can help identify and address leaks promptly. By reducing air leaks, businesses can improve the efficiency of their compressed air systems and lower their energy consumption.
When assessing the operating costs of a compressor installation, it is essential to consider all energy consumers, such as inlet filters, fans, pumps, dryers, and separators. Accurately assessing these costs allows for informed comparisons between different investment alternatives and helps identify areas where cost savings can be achieved.
To properly size the right air compressor, you'll need to determine how much force you'll need over a given time frame. This insight will provide you with the ideal pressure (bar) and cubic feet per minute (cfm) for your application.
If you work across multiple jobs, this will change your equipment needs. In this instance, it's recommended to get a variable speed drive (VSD) compressor capable of multiple pressure levels. Investing in the wrong size equipment can cause issues and unnecessary costs.
Purchasing an air compressor that's too small could overwork the machine and cause air leaks, resulting in wasted energy. Similarly, a machine that's too large will produce more air than needed, which also increases energy costs.
Although you might want to plan ahead and invest in a bigger machine than necessary, it's best to consider your current needs. You can always add equipment at a later time.
VSD rotary screw compressors come with benefits, including the ability to change speed and match pressure demands. These are the most optimal machines for most applications.
However, they also come with a comparatively high initial investment cost. That being said, VSD compressors are the most efficient, and usually cheaper to run. In fact, our IVR machines generate up to 30% energy savings. There's also energy recovery technology to help you reuse up to 75% of compression heat.
With all this, the main reason VSD machines save energy is how they operate. Regardless of use, fixed speed rotary screw air compressors work at the same speed to produce consistent air pressure. When VSD machines are faced with a lower air demand, they run at lower speeds, and only work at full capacity when generating air pressure for an application that requires this full capacity.
Of course, both fixed speed and VSD air compressors are generally a better choice than piston machines for heavy industrial use. The main reason for this is that piston air compressors usually require a rest period in between uses, and aren't built for all-day operations.
Implementing advanced control and regulation systems can optimize the operation of air compressors, leading to significant cost savings. A master control system can enable optimal operation based on different scenarios, improving safety and availability while reducing the risk of downtime. Utilizing a combination of compressors with varying capacities and speed-controlled motors can enhance efficiency and adaptability in air compressor installations.
Monitoring & Control Tools
You'll find some rotary screw air compressors are available with advanced monitoring and control tools. These features add insight, remote connectivity, and analytics for helping your system run smoothly. They're especially useful if you're operating multiple machines in a single facility.
These points are particularly related to the optional Intelligent CONnectivity System (ICONS), which provides data and insights to a computer tablet, or smartphone. This tool allows you to deal with maintenance issues before they add unnecessary costs and downtime.
Air compressor costs go beyond the actual machine, and include dealing with moisture in your system. Not properly addressing water vapor can lead to issues such as bacteria, contaminants, leakage, and other quality control issues.
This moisture forms when air is pressurized and heated through the compression process. When considering the overall cost of your machine, you'll want a highly efficient drying and filtration system.
In some instances, an aftercooler can allow you to invest in a smaller dryer. With this point, it's important to mention that an aftercooler is never a replacement for a dryer. An aftercooler alone won't cool your air to recommended PDP levels.
Regarding dryers, there are generally two main ways air is dried. One involves refrigeration cooling, and the other uses desiccant material to separate water from the air. In most cases, a "fridge" dryer is sufficient. However, for sensitive applications like food and medical, you'll need a desiccant dryer.
You can read more about this in our articles on dryers, which are useful when considering costs and needs.
Analyzing compressor investments based on life cycle costs is essential for making better financial decisions. This approach considers not only the initial investment but also the ongoing operating and maintenance costs over the compressor's lifespan. By focusing on life cycle costs, businesses can identify the most cost-effective solutions and achieve long-term savings.
How can energy-saving possibilities be utilized to reduce operating costs for air compressors?
Energy-saving measures such as energy recovery, pressure reduction, and optimal control and regulation systems can be implemented to minimize operating costs for air compressors.
What is the impact of working pressure on energy consumption in air compressors?
Higher working pressure results in higher energy consumption, with an average of 8% more power required for every 1 bar increase in pressure.
What are the advantages of monitoring and control tools for rotary screw air compressors?
Monitoring and control tools provide valuable insights, remote connectivity, and analytics, helping to ensure smooth operation of the system. These features are especially useful in facilities with multiple machines, allowing for proactive maintenance and preventing unnecessary costs and downtime.
Why is having a highly efficient drying and filtration system important?
Having a highly efficient drying and filtration system is important to ensure that the moisture and contaminants are adequately removed from the compressed air. This helps prevent issues such as bacteria growth, leakage, and other quality control problems.
Trust your air compressor maintenance to an expert
Everything mentioned in this article, is a simplified version of things to keep in mind when servicing your air compressor installation. Never perform any work on your screw compressor, piston compressor, air treatment or other equipment that you are not qualified to perform, but instead consult an expert.
Specialised air compressor experts know your system inside and out and are licensed to handle any situation, no matter what issue arises. Moreover, they’ll be able to provide pointers on how to better use your compressor.
Maintaining your air compressor is far more sustainable than buying a new one every few years, so make sure you take the time to really keep it up. If you’re looking to save money, refrain from buying a second hand compressor, and focus on quality parts and preventative maintenance.
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