Compressed air is an expensive energy. It is therefore worthwhile to optimize compressed air networks. The first step is the "knowledge" how and where to start with the optimization.
If one looks at the losses in a compressed air system, the leakage accounts for approximately 42% of the total losses. Other important aspects are overall system design and control.
Sample calculation
In a medium-sized production company (approx. 250 employees), a compressed air network with a compressor capacity of 960 m³ / h is installed. The compressor has a power consumption of 100 kWh and a running time of 80%. The system runs in two shifts, 16 hours a day and 276 days a year.
| Annual operating hours | Energy consumption | Energy price | Energy costs | Loss | Annual losses | |
| Before optimization | 4416 hours | 353,280 kWh | 0.06 €/kWh | 21,197€ | 25% | 5,300€ |
| After optimization | 4416 hours | 282,624 kWh | 0.06 €/kWh | 16,957€ | 5% | 848€ |
First step to saving costs
The precise and continuous analysis of the actual consumption of the compressed air system is the basis for system optimization. To do this, the operator must know the actual volume flows of the system, the distribution of the compressed air in the network and, ultimately, the volume flows during idle times - the amount of leakage. This data can be used to plan exactly where and which optimization measures have to be carried out. The solution is: the use of volume flow sensors. This records all the necessary data, such as leakage quantities, consumption and the distribution to the individual consumption points (for clear cost allocation). The maintenance intervals can also be flexibly adapted to the actual system status.
Process gas consumption
In many production processes, not only compressed air but also other gases are used. These can be protective gases such as CO2, helium or argon. The amount of fuel gas is relevant in combustion processes. For these applications, the use of a precise and pressure-resistant volume flow sensor is the optimal solution, on the one hand to save costs and on the other hand to ensure the safe process flow.