Role of Industrial Air Compressors in Energy Efficiency and Sustainability

An air compressor is one of those pieces of equipment a consumer scarcely sees, but it is indirectly used to manufacture everything we see. Given how it is widely used in industries, it is a major consumer of energy. If any manufacturing industry has to transition to a sustainable future with optimal energy consumption, they should look to their air compressors.

A study conducted by the US Department of Energy has found that air compressors consume nearly 10% electrical energy of an average factory. Compressors are frequently referred to as an industry's fourth utility because they consume a substantial quantity of energy. Here are various ways an industry can look to optimize their air compressor usage, while simultaneously reducing their carbon emissions.

Leakage Prevention

Air leakage is a major source of energy waste in factories. Eliminating air leaks can increase the efficiency of a compressor by 40%. In most cases the air leakage is not audible or visible, so as a precautionary measure, inspection must be carried out periodically. A 1/4^th inch 70kPa leak can cost about $2500. It is of utmost importance to have clean pipe networks with proper filters. Proper actions must be taken to ensure good quality air with leakproof equipment.

Cold Air Intake

If the compressor is indoors, there is a high probability it might be taking warm/hot air in its inlets. We know hot hair expands, so thermodynamically, more energy is needed to compress hot air. This results in high electrical energy consumption to compress the same quantity of air. This will also cut maintenance costs. Compressor intakes must be installed at the coolest place possible. This means taking the seasons into consideration and moving the inlet locations.

Heat Repurposing

Air compression generates heat, repurposing this heat using a heat recovery unit. This heat can be used to heat up spaces during cold seasons or to heat up water. This eliminates the need for the installation of additional systems to do the above functions. This greatly contributes to energy saving and reduces the environmental impact of the facility.

Noise Reduction

It is a well-known fact that air compressors are very noisy. It is not a pleasant noise to hear, appropriate measures must be taken to provide them with the required insulation so as to reduce the noise and provide a suitable working environment for the factory workers. Sound is a form of energy, so a part of the energy supplied is wasted as sound. Accomplishing this results in a quieter environment where workers are less disturbed, leading to more work done and energy saved from excess sound generation.

Filter Replacements

Filters are a key component in air compressors, they can arguably be what decides the life span of it. The quality of air which enters the cylinder is of utmost importance, any solid particles inside it can damage it or may lead to consumption of more energy. It is not just the filters in the long run, the entire unit must be given periodic maintenance. Integrating with monitoring systems to measure its performance and to view real-time data is a valuable investment any well-wisher can make. It can also prevent excess carbon emissions.

If any manufacturer wants to cut costs, he should first look towards the maintenance of their most used equipment. It is often overlooked how a factory’s equipment is treated. It’s easy for a factory to save costs by reducing maintenance on their equipment, but this in the long run eats up a lot of their capital. Some investments such as real-time monitoring can be expensive, but it’ll save costs in the long run. Environmental sustainability and cost-cutting can be done together if these operations are given more thought, it’s like hitting two birds with one stone. A long-term vision is paramount in any corporate decision.