Efficient compressed air system design

For good compressed air system design, finding and fixing air leaks is the single biggest saving you can identify. However, what can you do once you have found and repaired all the air leaks? Well, there is even more you can do to get the most efficient performance from your system to ensure you don’t waste money.

Below we give you some advice on how to best set up and operate your system for optimum efficiency.

Reduce the air inlet temperature

Compressing warm or hot air requires more energy than compressing cold air. Ensuring your compressor is sited in a cooler environment or drawing cooler ambient air from outside can save you up to 1% per 3C reduction.

Recover heat from your compressor

You can recover up to 90% of the heat generated by your compressed air system to use for heating. This requires minimal investment in many cases with the use of simple fans and ducting to give 10-25 C rise above the air inlet temp.

Optimize buffer capacity and location

Reduce the number of start/stop cycles required and increase the life of your compressor. As a rule of thumb size your receiver for 4 cfm/hp at 100 psig. It may be prudent to install more than one expansion vessel near the compressor to stabilize air flow, provide additional air cooling and moisture separation.

Pipe run material

Materials with a lower frictional coefficient such as aluminium, stainless steel, polyurethane etc can provide up to a 70% saving over Galvanised piping.

Correct connections

Incorrectly selected couplings can cost you up to 0.5 bar in lost pressure. Pressure drops can account for around 8% in electricity savings per 1 bar pressure drop eliminated.

The above detail just some of the ways you can optimise your compressed air system during the design phase as well as in use. Ensure you consult a specialist if you are at all unsure. Correct design at the outset will save you a lot of money but it’s never too late to save. Have your compressed air system audited today. For more information or to arrange a no obligation visit and quote contact us HERE.