Cement Manufacturers Association (CMA)

20 Minimize Compressed Air Leaks Leaks are a significant source of wasted energy. 20-30% of the compressor’s output is often wasted. A typical poorly maintained plant will have a leak rate equal to 20%+ of total compressed air production capacity. On the other hand, proactive leak detection and air compressor repair can reduce leaks to less than 10% of output. As you know, leaks are worse with higher pressure. By reducing system pressure your system will require less energy and also lower the leakage rates. Plant header pressures should be as low as possible to support the process because it minimizes compressor energy use and leakage. Compressed air leaks can contribute to problems with system operations, including. • Fluctuating system pressure, which can cause air tools and other air-operated equipment to function less efficiently, possibly affecting production. • Excess compressor capacity, resulting in higher than necessary costs. • Decreased service life and increased maintenance of supply equipment (including the compressor package) due to unnecessary cycling and increased run time. ENERGY MANAGEMENT Energy management is the means to control and reduce any organization’s energy consumption. It is reckoned that Industry uses more energy than any other end-use sector, consuming about one-half of the worlds. Controlling and reducing any organization’s energy consumption is important because it enables to reduce costs which increase as energy costs rise. Similarly, it has other aspects also, as under: - • Reduce carbon emissions, environmental damage, cost-related implications of carbon taxes and carbon footprint to promote a green, sustainable image. • Recognition of any company as a “green company”. • Reduce risk of energy price increase or supply shortages which seriously affect profitability or even sometimes make it impossible for any business/organization to continue. • Improves/increases productivity and can provide the products to customers at minimal cost. • Gives competitive advantage to organization/company. • Improve operational reliability and control What are the costs of compressed air generation? Compressed air costs are normally expressed in Nm³ (at 1.0 bar and 20°C to ISO 6358 or, for many compressor manufacturers, in m³ to ISO 1217:2009, Annex C). These can be determined using the sum of fixed and variable costs and using the annual delivery output of the compressor station: - Fixed costs Variable costs Compressor air intake per year In accordance with ISO 1217: 20 0 C, 1000 mbar + = Average Compressed air costs: 1,9 ct/Nm 3 Figure showing calculation of average compressed air costs