People who care

Increasing Profit & Contributing to Global Sustainability

(Reducing carbon footprint through effective compressed air management)

Presented by

Nick Hunt

Sector Business Development Manager

November 2010

The Automated Material Handling Systems Association

Agenda

• Introduction to Motivair

• Industrial energy Usage

• Improving Compressed Air Efficiency

• Summary

• Part of the privately owned £ 100m Leach Lewis Group

• Leading independent compressed air management company in Europe

• National service provider

Motivair

National Coverage

Service Support

Parts Distribution

EngineersWaltham Cross

Burntwood Brownhills

Cumbernauld

Servicing & repair

Flexible service plans

Equipment and Installations

24/7 emergency support

Consultancy & support services

Parts and accessories

Products & Services

Compressed Air

and

Industrial Energy Usage

Typical Compressed Air Installation

Compressor

Receiver

Dryer

Filter Filter Filter

Compressed Air Usage

10% of all industrial energy is used to power air compressors

Source: Guide 241, E.T.S.U., Best Practice Programme, Dept of the Environment

A typical rotary screw compressor

Whole life cost of ownership

Energy saving and Carbon Footprint Reduction

• Following a recent government-backed site survey of existing systems across ten sites, energy savings of around 35% were achieved

• Much of this could have been achieve beforehand with better compressed air management

Leakage Maintenance

Pressure Control

?

• Designing and operating a system at unnecessarily high pressures will waste energy and increase running costs

Pressure: Energy Consumption

Source: Guide 42, E.T.S.U., Best Practice Programme, Dept of the Environment

4 5 6 7 8 9 10 11

40

60

80

100

120

140 450

350

300

250

200

Pressure (bar)

Flo

w (l/s)

Po

wer

(kW

)

Pressure: Energy Consumption

Source: Guide 241, E.T.S.U., Best Practice Programme, Dept of the Environment

Power

Flow

Constant flow

Increasing pressure = more energy used

Control

?

Control: Energy Consumption

• Supplying an air main at high pressure than necessary is costly

• Basic cascade control of compressors won’t allow close pressure regulation

• Consider a multi-compressor system...

Sys

tem

Pre

ssu

re (

bar

)

Air Demand

Control: Less Pressure Saves Energy

100%

Required Pressure 7.0

8.5

9.0

9.5

8.0

7.5Wasted Energy

Over-pressure

Control: Variable Speed Drives

• Matches speed and power usage to air demand

• Drastically reduces energy costs during times when the compressor is not fully loaded

• Pressure remains steady

Control: Less Pressure Saves EnergyS

yste

m P

ress

ure

(b

ar)

Air Demand 100%

7.0

8.5

9.0

9.5

8.0

7.5

Leakage

?

• A survey of 47 typical UK industrial sites found that the average compressed air leakage rate was 18% of total demand

Leakage: Energy Consumption

Source: Guide 42, E.T.S.U., Best Practice Programme, Dept of the Environment

Leakage: Annual Cost

0 2 4 6 8 10 12

£30,000

£20,000

£10,000

£0

Hole Size (mm)

An

n. L

eaka

ge

Co

st

£5,000

£15,000

£25,000

£35,000

7.0 bar g7p per kW/hr8,000 hrs/yr

o

o

Leakage: Distribution System

Leakage: Leak Detection

• Specialist ultra sonic equipment can be used to detect leaks and tag locations

• Can be used to monitor pressurized systems regardless of the type of gas used

Maintenance

?

• If a compressed air system is not correctly managed it will become inefficient leading to wasted energy and increased running costs

Maintenance: Energy Consumption

Maintenance: Routine Servicing

• Regular servicing in accordance with manufacturer guidelines■ Service every 2,000 hours■ Motor & air end re-bearing after 20,000 hours

• Annual system audits, including leak detection

• Remote Monitoring can ensure maximum efficiency

Maintenance: Performance Monitoring

• System monitoring to ensure that it is operating correctly and efficiently

Leakage Maintenance

Pressure Control

?Reduced pressure= reduced energy

Increased control= reduced energy

Reduced leakage= reduced energy

Regular maintenance= reduced energy

People who care

Thank you

Any questions?

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