Installing a new compressed air system to optimise operating costs

Compressed air: an energy carrier that needs optimising in numerous sectors

Compressed air is an energy carrier that is frequently used in many sectors, particularly in the use of production machinery and specific pneumatic tools. Despite its abundant use, it is a complex medium to control, resulting in high operating costs. In an unmonitored installation, as much as 90% of the losses in heat generation and distribution can be linked to leaks. Compressed air costs can be contained by regularly analysing energy requirements and through technological monitoring. This applies to all new compressed air system.

Defining the requirements for the installation of a new compressed air system

Analysis of the current situation

• Determine the parameters of the existing installation, e.g. age, general condition, pressure level, minimum and maximum flow rate, energy consumption and associated costs, etc.

Analysis of compressed air requirements

• Given the considerable cost of using compressed air, it is recommended that, before any modifications are made, to determine whether compressed air is indeed the most suitable method for carrying out this task.
• Identification of the main characteristics of the compressed air consumption requirement, e.g. pressure level, flow rate, humidity, etc.
• Reduce network pressure as far as possible, according to the compressed air requirements (temporary reduction possible depending on requirements)
• Identification and elimination of potential leaks in the existing system. This will allow a more accurate estimate of compressed air requirements and avoid over-sizing the new installation.
• Is it necessary to replace the installation, or is it perhaps sufficient to optimise the installation?

Identify the appropriate compressed air installation to suit the particular purpose.

• Definition of the solution adapted to the needs and the specific application
  • Based on the needs analysis, define the solution in collaboration with a supplier or a consulting engineering office (specialised technical consultant).
  • In addition to the primary requirement, consider heat recovery, the installation of measuring points to monitor the installation and the compatibility of the existing network with the new compressor

• Evaluate other measures to improve system efficiency:
  • Automatic shutdown of the compressed air network outside operating hours
  • Installation of pressure-reducing valves upstream of consumers with low pressure requirements
  • Disconnection of consumers using magnetic valves
  • Renewing the system is an ideal opportunity to check whether it is possible to utilise the waste heat. The recovered heat could, for instance, be used to heat domestic hot water or rooms.
  • etc.

• Verification of operating permits for the project
  Where existing installations are to be adapted, and especially when setting up new installations, check the nomenclature of classified establishments.

• Drawing up specifications and requesting tenders

Subsidy application

Government subsidies

Applying for subsidies from electricity and natural gas suppliers

As of 2015, natural gas and electricity suppliers have been required to make energy savings for consumers as part of the obligation mechanism. Since then, energy suppliers have been offering support and advice services as well as subsidy programmes for consumers to implement energy efficiency measures.
The following suppliers offer this service to businesses:

• Enoprimes Enovos + SUDenergie
• SUDenergie
• Sudstroum

Once the compressed air system has been installed

• Schedule maintenance and periodic inspection of the system
• Regularly check the compressed air system for leaks (e.g. every two years and whenever changes are made to the compressed air system).