Optimization of compressed air systems

Vestec carries out analyzes of compressed air systems and, based on this information, can make recommendations to make the operation as efficient as possible. There are usually many ways to an efficient and reliable solution. Based on long experience and knowledge of requirements in different industries and applications, we can provide advice and guidance so that operations are as safe yet efficient.

A good example is from a recent customer visit where we delivered a Variable 55 frequency-controlled compressor with 18146 operating hours. During this time, the compressor has been idling (without producing compressed air) for one hour. This corresponds to an efficiency of 99,999945%.

There are many reasons why this is possible. Firstly, the compressor is dimensioned correctly in relation to the consumption profile of the customer. In addition, the compressor is frequency controlled, which means that the compressor adapts the production of compressed air to the need. Almig Variable compressors have a large regulation range, which means that the customer's consumption can vary widely without the compressor needing to switch to idle operation, but continue to produce compressed air with a lower capacity. Reduction or elimination of idle operation has a positive effect on the customer's electricity bill.

Frequency-controlled compressors are very common today, and fewer and fewer larger compressors are sold without frequency control. In some cases, it is still suitable with compressors that have a different type of regulation. The image below shows total operating hours and "load" hours. Load means that the compressor produces compressed air. This picture is taken from an Almig GEAR 110 (110kW) with proportional regulation. This means that it can regulate between 70-100% of the compressor's maximum capacity. In this case, this gives an efficiency of 99,9975% in relation to discharge/recharge cycles. This is exceptionally good for this type of regulation. In this case, a frequency-controlled compressor could be considered before further increasing the efficiency, but this must then be assessed against the investment cost of a frequency-controlled compressor.

Vestec has a lot of expertise in making compressed air systems more efficient. By taking environmentally friendly measures that save energy, you can get support from ENOVA for your investments. This is something we can assist with and help with.

The first thing we need to do is make an energy balance measurement. We call it an EBS measurement. Read more about it here. Based on this, we find the way forward.

Do not hesitate to contact. We are here to help you and your business.