Reducing total cost of Compressed Air ownership with energy air audits

Compressed air accounts for approximately 20% of total energy consumption in industry. CompAir South Africa outlines the benefits of performing energy air audits and how they can help realize improved efficiencies within your businesses. Efficient use of energy and Reducing Life Cycle Costs Energy costs represent over 80% of the total cost of ownership of generating compressed air. Growing energy costs are a key driver of industry operational costs. Faced with these realities, CompAir SA uses data-logging equipment to pinpoint inefficiencies, optimise performance, reduce leaks and manage processes. Failing to rectify inefficient practices leads to unnecessary cost burdens and impacts on equipment performance. Conducting a thorough and detailed energy audit to identify inefficiencies is an excellent way to reduce the cost generating compressed air. The graph below indicates the typical potential for managing the cost of compressed air. Small leaks equal to large sums of waste energy Pipework leakages are a large factor in compressed air energy wastage, accounting for 35-50% of total air consumption. There are many reasons for leaks in a compressed air system, corrosion inside piping, leaking hoses and piping, couplings, flanges and pipe joints. Such oversights and deterioration can be expensive – according to the below table, just one 5mm leak could cost a company over R 90 000 a year in wasted energy. Example for a calculation of leakage cost Leak Ø (mm) Air loss at 6Bar (l/s) Energy loss kWh at 6 Bar * Cost R at 6 Bar 1 1.2 0.3 R 3,285.00 3 11.1 3.1 R 33,945.00 5 30.9 8.3 R 90,885.00 10 123.8 33 R 361,350.00 * kWh x R 1.25 x 8760 hrs/year (Other loss calculations available upon request) Heat Recovery As well as identifying leakages, an energy audit can be used to quantify a compressor’s possible heat potential. Because 94% compressor-generated heat is recoverable, this can prove invaluable for companies looking to make operational efficiencies. Heat can be recovered through a variety of processes. This includes installing an energy heat recovery unit fitted to the oil circulation system – recirculating warm air from the compressor to a local working area for heating or heated water is required, such as central heating, hot water washing and steam systems. The Process CompAir SA will carry out a pre-assessment survey before they conduct an energy air audit with a customer. This looks at a range of variables that affect compressed air usage, such as: compressor kW sizes; flow, dew point, pressure and temperature measurements; time required to perform a leak survey; shift patterns; cost of electricity on site; and any obvious signs of leaks. Please contact your local sales or service representative or contact Francois De Jager francois.dejager@compairsa.comon +27 (0)76 098 4986 for additional information. About the CompAir Industrials Group CompAir South Africa is a wholly owned subsidiary within the Gardner Denver Group of companies, your ultimate source for pressure and vacuum. CompAir SA sells, services and hires air compressors (diesel and electrical), parts, filters, dryers, control equipment, rockdrills, vacuum and blowers and related products to all industries via its extensive branch and distributor network that services South Africa and sub-Saharan Africa. CompAir SA strives to achieve customer satisfaction by continually improving processes and services, to ensure that the company consistently meets or exceeds its customers' expectations. In South Africa, CompAir was established in 1927 and celebrates 90 years and that, coupled with Gardner Denver's 160 years of industry expertise, makes us the company of choice giving ultimate industry expertise that only Gardner Denver can provide.