People who care Increasing Profit & Contributing to Global Sustainability (Reducing carbon footprint through effective compressed air management) Presented by Nick Hunt Sector Business Development Manager November 2010 The Automated Material Handling Systems Association
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People who care Increasing Profit & Contributing to Global Sustainability (Reducing carbon footprint through effective compressed air management) Presented.
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People who care
Increasing Profit & Contributing to Global Sustainability
(Reducing carbon footprint through effective compressed air management)
Presented by
Nick Hunt
Sector Business Development Manager
November 2010
The Automated Material Handling Systems Association
Agenda
• Introduction to Motivair
• Industrial energy Usage
• Improving Compressed Air Efficiency
• Summary
• Part of the privately owned £ 100m Leach Lewis Group
• Leading independent compressed air management company in Europe
• National service provider
Motivair
National Coverage
Service Support
Parts Distribution
EngineersWaltham Cross
Burntwood Brownhills
Cumbernauld
Servicing & repair
Flexible service plans
Equipment and Installations
24/7 emergency support
Consultancy & support services
Parts and accessories
Products & Services
Compressed Air
and
Industrial Energy Usage
Typical Compressed Air Installation
Compressor
Receiver
Dryer
Filter Filter Filter
Compressed Air Usage
10% of all industrial energy is used to power air compressors
Source: Guide 241, E.T.S.U., Best Practice Programme, Dept of the Environment
A typical rotary screw compressor
Whole life cost of ownership
Energy saving and Carbon Footprint Reduction
• Following a recent government-backed site survey of existing systems across ten sites, energy savings of around 35% were achieved
• Much of this could have been achieve beforehand with better compressed air management
Leakage Maintenance
Pressure Control
?
• Designing and operating a system at unnecessarily high pressures will waste energy and increase running costs
Pressure: Energy Consumption
Source: Guide 42, E.T.S.U., Best Practice Programme, Dept of the Environment
4 5 6 7 8 9 10 11
40
60
80
100
120
140 450
350
300
250
200
Pressure (bar)
Flo
w (l/s)
Po
wer
(kW
)
Pressure: Energy Consumption
Source: Guide 241, E.T.S.U., Best Practice Programme, Dept of the Environment
Power
Flow
Constant flow
Increasing pressure = more energy used
Control
?
Control: Energy Consumption
• Supplying an air main at high pressure than necessary is costly
• Basic cascade control of compressors won’t allow close pressure regulation
• Consider a multi-compressor system...
Sys
tem
Pre
ssu
re (
bar
)
Air Demand
Control: Less Pressure Saves Energy
100%
Required Pressure 7.0
8.5
9.0
9.5
8.0
7.5Wasted Energy
Over-pressure
Control: Variable Speed Drives
• Matches speed and power usage to air demand
• Drastically reduces energy costs during times when the compressor is not fully loaded
• Pressure remains steady
Control: Less Pressure Saves EnergyS
yste
m P
ress
ure
(b
ar)
Air Demand 100%
7.0
8.5
9.0
9.5
8.0
7.5
Leakage
?
• A survey of 47 typical UK industrial sites found that the average compressed air leakage rate was 18% of total demand
Leakage: Energy Consumption
Source: Guide 42, E.T.S.U., Best Practice Programme, Dept of the Environment
Leakage: Annual Cost
0 2 4 6 8 10 12
£30,000
£20,000
£10,000
£0
Hole Size (mm)
An
n. L
eaka
ge
Co
st
£5,000
£15,000
£25,000
£35,000
7.0 bar g7p per kW/hr8,000 hrs/yr
o
o
Leakage: Distribution System
Leakage: Leak Detection
• Specialist ultra sonic equipment can be used to detect leaks and tag locations
• Can be used to monitor pressurized systems regardless of the type of gas used
Maintenance
?
• If a compressed air system is not correctly managed it will become inefficient leading to wasted energy and increased running costs
Maintenance: Energy Consumption
Maintenance: Routine Servicing
• Regular servicing in accordance with manufacturer guidelines■ Service every 2,000 hours■ Motor & air end re-bearing after 20,000 hours
• Annual system audits, including leak detection
• Remote Monitoring can ensure maximum efficiency
Maintenance: Performance Monitoring
• System monitoring to ensure that it is operating correctly and efficiently
Leakage Maintenance
Pressure Control
?Reduced pressure= reduced energy
Increased control= reduced energy
Reduced leakage= reduced energy
Regular maintenance= reduced energy
People who care
Thank you
Any questions?
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