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The world is changing. Higher demands of consistent, on-time manufacturing are combined with an increasing focus on energy optimization and a sustainable perspective on all aspects of production.

Industrial compressed air systems can have a leakage of up to 60 %, which makes it one of the most urgent – and profitable – areas of an industry to optimize. Take the Enersize Energy Optimization Quiz and experience the first step in becoming one of the Change Masters of your organization – and the world.

Major energy saving is needed

The basics

  • Compressors use about 10 % of all electricity consumed in industry
  • Up to 60 % of this energy is wasted due to leakage and inefficient maintenance.
  • Compressed air leaks alone accour for 25-30% of compressed air use.

As you can see, reducing air leaks stands for 42 % of the energy savings potential in industry today.
(Source: European Comission, SAVE Programme)

Dig deeper

How is air compressed and why is it so expensive?

Step 1: The air is trapped in a tank, cylinder, or similar container

Step 2: The space in the tank becomes smaller, which forces the air molecules closer together. The compressed air remains trapped in this smaller state, waiting to expand again, when it’s ready for use via a hose.

Step 3: Due to that the air molecules are forced closer during compression heat is generated! This needs to be attended to by cooling and drying the compressed air before it is used. Most compressors systems incorporate aftercoolers to reduce the temperature in combination with separate dryers.

Note: That there are different styles of air compressors, like rotary screw compressors that make use of dual spinning screw pushing the air down and compressing it.

 

 

Reducing Carbon footprints can be easy

The basics

US Department of Energy estimates that half of all compressed air is lost.

Globally, there is a focus on embracing sustainability like never before. Every industry is part of the ambitious global effort to deliver the 2030 promise of the UN Sustainable Development Goals.

Organizations are expected to initiate ambitious actions to deliver the Goals by 2030. 

Dig deeper

  • Educating yourself to create awareness together with specialized software to reduce compressed air leakages will successfully lower the company’s energy costs and CO2 emissions by 20-30%. 

  • More and more web-enabled devices are gathering data as part of the Internet of Things (IoT). 

  • Production becomes smart, intelligent and autonomous. Production lines will make their own decisions and human intervention will only be needed when things go wrong. 

  • Automation is becoming faster, more capable and ever-present, while Artificial intelligence (AI) is already driving the design of revolutionary software experiences. AI and Machine Leaning (ML) are the keys to automation and digital transformation. We will see ever more cloud applications feature AI and  ML capabilities, while an inspiring amount of data is managed autonomously. 

Audit today and monitor the future

The basics

Today’s technical solutions make it easy and quick to audit a compressed air system. Any leak is detected whithin a few days – add a week or two, and the system is repaired to create big savings.

Compressors require much energy and only a fraction of the power is usable compressed air. Furthermore, the heat created by the compressor creates condensate which needs to be cooled & dried before letting it in to the factories piping system. This also increases the energy cost. 

Compressed air needs are defined by the air quality, quantity, and level of pressure required by the end uses in your plant. Analysing needs will ensure that a compressed air system is configured properly so that a clean, dry and stable supply of compressed air can be delivered at minimal cost.

Dig deeper

Detect leaks 

The best way to detect leaks is to use an ultra- sonic acoustic detector, which can recognize high frequency hissing sounds associated with air leaks.  A leakage survey will help you find, grade and document leaks.

Repair leaks 

Leaks are a significant source of wasted energy in a compressed air system, often wasting as much as 25-30% of the compressor’s output.

Compressed air leaks can also contribute to problems with system operations, including fluctuating system pressure, excess compressor capacity, or decreased service life and increased maintenance of supply equipment.

Monitor and maintain 

Fixing leaks once is not enough. Incorporate a leak prevention program into your facility’s operations. It should include identification and tagging, tracking, repair, verification, and employee involvement. Set a reasonable target for cost effective leak reduction—5-10% of total system flow is typical for industrial facilities.

Future proofed
A continuous monitoring and maintenance program will help you track the essential key performance indicators (KPIs) for your compressed air system.

Taking care of your air means taking care of you

The basics

There is a reason compressed air is able to drive complex industrial processes – even a stream of a few bars can do great harm to a human body. Never compromise on your own safety and carry the required safety equipment!

It is very important to keep the surrounding workspace clean. This in order to not have debris flying around due to the magnitude of compressed air which also may cause an injury. Standard protective equipment shall always consist of glasses, gloves, and ear protection.

Dig deeper

Is compressed air safe?

  • As far as an energy source, compressed air is simple, safe, clean, and efficient.
  • It is a non-combustible, non-polluting utility
  • There are no dangerous exhaust fumes or other harmful by-products when compressed air is used.

 

Can compressed air kill you?
Compressed air can be dangerous when used improperly or if air receiver tanks aren’t properly maintained. It is therefore vital that operators always need to follow the guidelines set by manufacturers.

Never:

  • Point air at an open wound as it can obstruct an artery and result in an embolism.
  • Clean off your clothes using an airstream, as it may cause serious injury. E.g., debris can fly into the eyes.
  • Blow towards a colleague as a joke.
  • Blow into a mouth, as it may rupture the lungs.
  • Blow into ears as it can rupture the eardrums

Take the Quiz!

Welcome to your Take the Enersize Energy Optimization Quizz


Take the Quiz!

Welcome to the Enersize Quiz! It contains of 11 questions and you'll find all the answers to them here on the Enersize website. We wish you the best of luck and that you'll enjoy the quiz!


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