IN THE first quarter of 2022, short-term gas prices on the largest European exchange were five times higher than their 2021 average , and future markets are pricing European gas at up to three times its 2021 levels for at least the next three years. 

The latest Office for National Statistics business insights update (dated 19 May) also cites rising energy prices as a key issue, with 20% of businesses raising concerns.

Against a backdrop of rising inflation of goods and services, many businesses will also be mindful of their environmental impact. Driven by their own corporate social responsibility agenda, as well as meeting stringent Government targets as industry moves towards net carbon zero, operators are increasingly conscious of the sustainability credentials of new capital equipment.

The benefits of variable speed compressors

Variable speed compressors can play a role in helping businesses to reduce their electricity consumption and contribute to long-term sustainability goals.

Traditionally, compressors have used fixed speed motors, which means they run at a constant speed, and produce a fixed amount of compressed air per minute, regardless of air demand. In most scenarios, it is unlikely that the exact amount of compressed air generated will be required. This means the compressor can potentially be creating compressed air that ends up being wasted. 

In addition, fixed speed compressors run unloaded, as the stress of an engine start-up would put pressure on the motor. This can be a waste of energy as the machine is running without producing any compressed air. 

In contrast, variable speed compressors can start and stop under full system pressure. They use an intelligent drive system to alter the speed of the motor constantly and to match the air generated to the required process demand. This allows for the required high speeds for compression, while generating sufficient flow to meet plant requirements, hence minimising power consumption.

This technology can have a positive impact on businesses productivity, efficiency and sustainability levels. When compared with a fixed speed compressor, a variable speed model can achieve energy savings of up to 30%, and can help reduce power surges, avoiding peak currents from starting the compressor’s motor. Furthermore, precise electrical controls ensure motors can be easily slowed down, stopped, or revved up. 

The risk of leaks is minimised through the lower system pressure that is achieved with a variable speed drive. Minimising leaks in a compressed air network is another key benefit, and one of the most important energy saving measures for businesses. The Carbon Trust reports that a 3mm hole could cost over £1,000 a year in wasted energy – not to mention the associated impact on the environment, from generating all this lost energy.

The need for data analytics

Any investment in variable-speed technology should also be supported by comprehensive data analytics; to ensure the compressed air system is operating at peak performance.

Having a comprehensive service and maintenance strategy in place will stand operators in good stead when looking to improve a system’s total cost of ownership.

From a total cost of ownership perspective, it makes smart commercial sense to invest in a system that requires as little maintenance as possible and can be serviced easily.

Today, the Internet of Things and data analytics can help operators to understand how efficiently a compressor is running, and whether any improvements can be made. These insights will not only help highlight any potential issues now, but also enable operators to forecast any potential future problems, based on deteriorating machine performance.

Predictive maintenance models based on real-time data can be established to help reduce energy consumption, improve process efficiencies and limit any risks. Connectivity continues to be a key focus in the CompAir portfolio, with the company's iConn service offering intelligent insights that help operators monitor a system's performance in both real-time and remotely.

Accessible from smartphones and tablets, the browser-based system ensures users can proactively manage any potential issues that arise, reducing associated downtime and guaranteeing the system is performing as required.

Using genuine spare parts

Another factor to consider is genuine spare parts and lubricants for compressor systems, which can impact on whole life costs. Non-genuine spare parts and lubricants for machinery can be tempting when trying to cut back on costs, but a manufacturer’s original parts are always recommended. In some cases, a non-genuine alternative can cause real damage, resulting in not only an expensive repair bill but unexpected and costly downtime as well.

In contrast, genuine spare parts will have been manufactured to meet the same standards as the equipment they are intended for. These will have passed the manufacturer’s stringent testing regimes, in a quality-controlled environment, to ensure the system in question continues to operate reliably.

Energy savings in action

The Metal Drum Company, a manufacturer of steel drums, is one such organisation to have benefitted from installing variable-speed compressors, saving £23,000 per annum.

Thanks to a programme of energy-efficiency improvements, The Metal Drum Company is benefitting from a new, CompAir L160 RS, variable-speed drive machine at its main Chilton site, delivering payback in just 3.5 years; alongside a smaller L75 machine, offering 3.7 years' payback at its Hull facility – from CompAir distributor, Air Compressors and Blowers North (ACB)

The CompAir L160 RS has proved ideal for the larger air volumes required at the Chilton site, with predicted energy savings of £15,000 per annum.  

The L75 RS compressor at the Hull site is on track to achieve energy savings of £8,000 per annum. With higher air delivery, a new, compact footprint of only 2.23m2 and a lower noise level, the unit has been sited in the main production area, without any concerns.  The new machine offers efficiency improvements of up to 6.8% over previous models, and a higher flow rate up to six per cent from the brand new airends, delivering significantly lower lifetime costs.

Colin Mander is business line director at CompAir

For more information: 

www.compair.com

Tel: 0114 398 4488

BOXOFF

CompAir highlights new environmental campaign 

The recent COP 26 summit, coupled with rising energy bills is driving more and more businesses to consider their electricity consumption, alongside their impact on the environment. Compressed air generation is said to account for as much as 10% of all the electricity consumed by industry, so CompAir is incentivising its customers to lower their energy bills and their carbon footprint, by investing in the latest energy-efficient compressed air technology.

The new environmental campaign, in partnership with Carbon Footprint, commits to planting one tree for every CompAir or Hydrovane variable-speed compressor sold in the UK.

The campaign aims to plant hundreds of trees before the end of the year, across a variety of regions in the UK – one for each energy-efficient compressor purchased.  

In addition, the company will be supporting a biodiversity reserve project in Rimba Raya in Borneo, Indonesia, with the aim of offsetting 200 tCO2e of its own emissions from its operations.