Optimising compressed air system management in the company
Energy
Mobility and transportation
Manufacturing
Transport
Administration
Agriculture, viticulture
Craft Industry
Aid and care sector
Commerce
[ Detailed version of the measure ]
Last update: 30/08/2024
Available tools
Possibility of assistance
Subsidies available
Control operating costs related to compressed air systems in the company
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, losses during heat generation and distribution due to leaks can be up to 90 %. Compressed air costs can be contained by regularly analysing energy requirements and through technological monitoring. This measure is required for every new compressed air system.
Given the very high cost of using compressed air, it is advisable before any optimisation to determine whether compressed air is the best way to perform this task.
Reduce network pressure as far as possible according to compressed air requirements (temporary reduction possible depending on requirements) Identify and eliminate leaks in the existing system.
To take your compressed air optimisation project a step further
The main tasks of a consulting engineering office (technical process specialist) within the scope of compressed air system optimisation are as follows:
carry out an inventory of compressed air infrastructure
analyse energy consumption in relation to compressed air production
check for leaks in the network, particularly at consumer connections.
Implementation of compressed air optimisation measures
Appointment of a compressed air delegate within the company
The responsibility for compressed air is delegated to a designated employee within the company. This person’s role is to keep an eye on the compressed air equipment and is responsible for ensuring that it is continuously inspected.
Organise periodic inspections (to be carried out by an approved body).
Optimise the installation with the conclusions of the inspection reports .
Setting the correct compressed air pressure level
Each compressed air consumer and compressor is designed to operate at a specific pressure. It’s a question of finding the right balance between production, the network (with its load losses) and the various consumers.
Implementation of best practices for compressed air system use
Raising awareness among employees who use compressed air
Adapt operating times to work schedules, e.g. overnight or weekend shutdowns, temporary shutdowns, etc.
Waste heat recovery:
Renewing the system is an ideal opportunity to check whether waste heat can be used. The heat recovered can be used to heat domestic hot water or premises. The use of waste heat with a heat exchanger is generally economical if the compressor size is 15 kW or larger. If conditions are ideal, heat recovery can also make sense with smaller compressors.
The following points should be clarified:
Can waste heat from the compressed air system be used for warm-air heating in winter?
Can you combine a heat exchanger with the installation (used to support heating, domestic hot water production or process heat)?
Does it make economic sense to use waste heat?
Can I remove waste heat from the compressor when it’s not in use (in summer)?
Is the system still fit for purpose and efficient enough (installation of a new compressed air system)?
Good to know
Small investments can save even more energy:
Add an automatic trigger system
Installing pressure-reducing valves
Replace timed condensate traps
Equip permanent consumers with solenoid valves
Replace old fittings with low-loss materials
Subsidy application
Please note: any application for government or non-government subsidies must comply with the “incentive effect”, subject to compliance with the subsidy conditions.
In order to respect the “incentive effect”, no binding commitment (signing a quotation; paying a deposit) may be made BEFORE having received the agreement in principle from the State or the electricity and natural gas supplier following an application for subsidy.
Flat-rate €5,000 grant for small and medium-sized businesses for projects to reduce their environmental impact, costing between €6,650 and €25,000 excluding VAT.
N.B. Government subsidies cannot be combined for the same project.
Assistance from electricity and natural gas suppliers for compressed air systems
Since 2015, natural gas and electricity suppliers have been obliged to deliver energy savings to consumers as part of the obligation mechanism. Since then, energy suppliers have been offering support and advisory services, as well as assistance programs for consumers to implement energy efficiency measures.
The following suppliers offer this service to businesses:
Manufacturing
Transport
Administration
Agriculture, viticulture
Craft Industry
Aid and care sector
Commerce
