Energy efficiency is not a passing fad but a long term business prerequisite
May 1st 2006

Boge's four-step approach to compressed air energy management has already assisted many users in optimising their energy usage. Geoff Taylor, managing director of Boge Compressors and a Director of the British Compressed Air Society, reviews the process

Creating sustainable compressed air energy efficiencies for our customers has long since been at the top of the Boge agenda.

The effect of the energy tax (or CCL) continues to be a driving force that encourages industry to become more energy efficient or be faced with hefty energy bills. More significantly the focus to reduce energy consumption has been highlighted by the recent meteoric rise in electricity prices. In fact, it was recently reported that in the past three years alone, electricity prices have risen between 38 and 85%!

Yet, compressed air remains one of the easiest technologies with which to realise quick, significant and sustainable energy consumption reductions.

Some time ago Boge introduced the four-step approach to compressed air energy management, which begins by benchmarking an existing system and then provides for continual assessment and validation of the ongoing live air system. This comprehensive methodology maps out the path for the compressed air user to follow in order to generate sustainable energy savings.

Step 1; Audit

To establish the benchmark a system must be comprehensively audited by evaluating generation, treatment, distribution and process usage.

Leakage is a major energy wastage culprit that can rapidly be assessed within the audit. An ultrasonic leak detector will locate system leakage precisely. Thereafter periodic leak detection as part of an overall maintenance schedule has proven to be extremely popular and a beneficial added value service for customers who wish to maintain a leak free, energy efficient air distribution system. Crown Speciality Packaging is one such customer that has benefited and created significant energy cost reductions through leak detection and repair. Chris Nolan, the Site Service Team Leader recently identified that in the space of just a couple of months their compressed air energy consumption has been reduced by 25% simply by undergoing a regular leak detection programme with Boge.

Step 2; Optimise

Once an audit is completed, the whole compressed air system can be optimised to reduce and if possible eradicate the identified energy waste and misuse. In many cases the recommended changes will only incur low costs - if any.

Unfortunately the process of saving energy for many businesses then ends here!

The system was audited and optimised, energy savings were identified, leaks repaired - job done? Reality dictates that this is not the case. The post audit period, along with a commitment to an on-going re-audit process as the system dynamics change, are just as important.

Step 3; Post-audit

After the whole system has been optimised the system efficiency (kW/m3) should be compared with the original benchmark in order to validate changes that have been implemented. By doing so the evidence to justify any further action that has been recommended is provided.

At the same time it is possible to calculate a 'payback time' for any investment that may be required to implement the further on-going energy savings.

Step 4; Continual improvement

Where appropriate the installation of a Boge MCS Professional Plus energy management system will make a massive contribution to a system's long term efficiency and cost control.

The MCS Pro+ will continually audit a compressed air system, ensure that the compressors run as efficiently as possible, maintain the system pressure precisely and ensure ongoing cost optimisation.

The inclusion of a control system not only underpins the short-term savings but also provides the basis for an on-going reporting system where the system efficiency (kW/m3) is continually reviewed.

Cadbury Trebor Bassett at Sheffield has enjoyed such benefits since introducing the MCS Pro+ into their compressed air system. Following initial optimisation the annual generation costs for compressed air reduced by 10% with overall system efficiency having improved by 13.67%

By following the Boge four-step approach to compressed air energy efficiency has proved to be a winning formula that continues to generate on-going sustainable energy savings for our customers.

Undeniably, the pressure to reduce energy costs in industry has only grown with increased demands of a legislative and financial nature. Nowadays all Plant managers should have compressed air efficiency and the resultant energy savings, as a top priority in the short term, but also an integral part of their long term compressed air maintenance plans."

Visit www.boge.co.uk for further energy tips, solutions and interest free finance for SME's via the Carbon Trust.

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