Consultant - Screw compressor

It’s a proven fact that about 70% of an air compressor’s lifetime cost comes from power consumption. Have you assessed what compressed air is costing you? Here are 10 expert insights to help you keep a tab on the electricity bill.

• LOWER THE PRESSURE We all know that working under pressure can be hard! Every additional bar of pressure can increase your power consumption by 7%. Set your air compressor at the lowest possible pressure for a specific application. Remember that increasing pressure does not compensate for a pressure drop in the system due to leaks, faulty piping, or choked filters. Install a pressure regulator for better control. It’s also important to calibrate your pressure gauges at quarterly intervals.
• CHANGE FILTERS ON TIME While replacing air filters is mandatory to maintain the quality of air, it is also an energy saving opportunity. Delaying an air filter change costs you more than you think! Clogged filters can lead to pressure drops and hamper efficiency. Ensure on-time service for a healthy compressed air system.
• INVEST IN PRE-FILTERS Not only do pre-filters (also known as coalescing filters) help purify air by removing oil and water but also particulate matter to a certain extent. Installing pre-filters for suction air and cooling air can extend the life of your compressor and its consumables.
• CLEAN UP Besides keeping your air clean, ensure that you give your compressed air system a thorough dusting every few months. Presence of sludge, dust or grime can have a big impact on the efficiency of the compressed air system. Pay special attention to compressor coolers and heat exchangers. Consider investing in a dedicated low pressure air compressor and air line for cleaning to save power.
• PICK THE RIGHT DRYER Selection of the right sized air dryer for your compressed air system is crucial. Make sure the energy consumption of the dryer is in proportion to the demand. An oversized dryer can add to your electricity bill significantly.
• CONSIDER A VFD Screw compressors should run under full load. If the usage pattern varies, consider a Variable Frequency Drive (VFD) for upto 35% reduction in energy cost. A VFD helps regulate the energy consumption based on demand fluctuations, ensuring energy efficiency. ELGi’s VFD has helped clients realize up to 215% savings in maintenance and energy cost with payback as low as 7 months.
• PERFORM QUARTERLY MAINTENANCE CHECKS The importance of maintenance cannot be overemphasized. Regular maintenance can help you identify and accurately measure leaks in the circuit. They also reduce the chances of breakdowns leading to maximum uptime and productivity.
• PREVENT MISUSE OF AIR Wasted air is wasted money. Invest time and money in training employees for efficient compressed air management. Create maintenance logs and update them on a regular basis, recording abnormalities or leaks in the systems. Systematically label leaks with proper tagging and prioritize repairs and plugging of leaks.
• RECOVER HEAT It’s common knowledge that heat is produced during the process of air compression. If not used judiciously, all the heat energy goes to waste. Over 90% of the heat produced can be recovered and utilized for heating air or water at the facility.
• GET AN AIR AUDIT Air audits enable companies to work with experts in the field and get valuable insights into their plant’s compressed air utilization. ELGi’s air audits chart out a customized and comprehensive energy management plan for your needs. Over the years, we have helped save millions of dollars in energy costs. Request an air audit now