Understanding Compressed Air Preparation Fundamentals Can Help Reduce Industrial Energy Usage and Deliver Operational Efficiencies
Escalating energy costs are impacting everyone.
And while domestic users dominate the headlines, the competitiveness of many high energy industrial processes are also being financially affected by the current unprecedented hike in the price of the energy.
But taking a practical review of a vital, but often overlooked industrial power source – compressed air – can help deliver operational efficiencies and, critically, help to reduce energy consumption and associated costs.
The key to this is an effective compressed air programme using air preparation equipment. By understanding the fundamentals of air preparation to optimise equipment performance within an industrial setting, users can obtain several important benefits, including overall reductions in energy consumption.
Compressed air is commonly referred to as the fourth utility after electricity, water, and gas. Many manufacturing facilities will have compressed air on site. As with the other utilities, the conditioning of compressed air is important when it comes to the life optimisation of the critical equipment that runs on it.
As a result, the use of air preparation equipment to meet compressed air requirements is common in industrial environments, and it It should be stressed that the benefits of having an efficient and effective compressed air system are tangible, influencing safety, equipment performance, air consumption running costs and the commercial impact of highly-priced energy.
The principal method for producing compressed air is via an electric motor. The more compressed air used, the higher the running cost. Optimising and reducing air consumption levels not only cuts the direct cost of energy, but areas such as compressor maintenance - which is running hours based - will also benefit in the long run.
Measuring and monitoring
A central part of any good air preparation strategy is to examine actual performance. For example, getting out onto the factory floor and listening for the tell-tale sign of an air leak is a great place to start.
Likewise, measuring, monitoring, and adjusting pressure settings to optimum levels can also help to save on energy.
Reduction of compressed air usage through optimisation strategies such as reducing/eliminating leaks and running pressure optimisation, all contribute to lower air usage, energy consumption and, consequently, the sustainability benefits of a reduced carbon footprint.
The role of the FRL – filter, regulator, lubricator
Improved air quality can be achieved by having good filtration, because in its absence, contamination and water in the airline will inevitably lead to unwanted and potentially expensive breakdowns. Industry and application-specific needs for higher filtration levels can also be found within the manufacturing process. and it is therefore important that the right filter and the right filtration level requirement is understood and implemented.
Following filtration, downstream compressed air pressure should be optimised via regulation.
A regulator’s function is to reduce the secondary or downstream pressure. Pressure reduction has an inherent safety benefit as running at optimum pressures lower than the primary level will reduce stress on the pipework and components downstream of the regulator.
A regulator also removes pressure fluctuations from the process. Best practice calls for a primary pressure that is at least 1 bar greater than the desired secondary pressure setting on a general-purpose regulator.
In a move to further optimise performance, it is worth considering the use of additional regulators with actuators in applications where the work is only being done in one direction. Here, reducing pressure will reduce overall air consumption within a system which means lower running costs and reduced energy needs for compressors.
It may be feasible to run the return direction or cylinder stroke at a lower running pressure. Regulators best suited for these types of applications are those with a built-in non-return valve or a reverse flow function. In fact, for every one bar pressure reduction users are able to make, it is estimated this equates to an approximate 7% saving in running costs.
In addition to the filter and regulator, a combination unit - the filter regulator - that has the two functions combined in one unit, can be a cost-effective way of conditioning air to meet needs and save space in challenging industrial environments.
Service importance
Fully serviced parts operate most effectively. It is worthwhile considering the timescale since the air preparation equipment was last serviced. In addition, any pressure drop over time will increase compressor use and any flow restrictions can slow the machine down – again restricting output.
Finally, make sure general-purpose elements are replaced annually. Check if the secondary pressure set is where it needs to be. Make sure the lubricator oil level is correct and compatible with the pneumatic equipment and assess if the oil drip rate is set to deliver the right amount of oil needed on the machine.
Norgren is ideally placed to assist design and maintenance engineers when it comes to the correct assessment of their compressed air preparation needs. We can provide a range of product solutions - including the flagship Excelon Plus air preparation range – as well as an easy-to-use online configurator tool. Customers can also access our team of expert application engineers and lifecycle support so that they can begin to take a holistic approach to their compressed air preparation needs to optimise operational efficiencies and cut rising energy costs.
Want to find out more?
Correct compressed air preparation is essential for optimum performance of your pneumatic ring-main and equipment. Norgren are experts in the FRL arena, where our ranges have been at the forefront of industry for many years. Our product ranges, including Olympian Plus and Excelon, are available from individual to combination units.