A number of solutions are available to help users to maximise the efficiency of compressed air installations through improved reliability and availability and reductions in energy consumption and carbon dioxide (CO₂) emissions.

“The production of compressed air is one of the biggest energy consumers in manufacturing and processing plants, expending roughly 4% of the total global energy consumption,” notes Atlas Copco Compressor Technique advanced service sales engineer Jaydon Prinsloo. “Consequently, energy is the most expensive component in the total cost of producing compressed air, making up to 70% of a compressor’s life cycle costs.”

“In our continuous quest to deliver the most efficient compressed air solutions, our focus is on engineering more energy-efficient machines and shaping state-of-the-art technologies,” continues Prinsloo.

Atlas Copco highlights its analysing, optimising and monitoring solutions that are designed to assist users to gain the full benefit from air compressor systems, while also reducing operating expenditure.

The company’s AIRScan system is used to conduct a comprehensive audit of a compressed air installation to establish system efficiency and identify potential energy saving opportunities. The software generates a report that includes problem evaluations and recommendations of solutions.   

Quick fixes that deliver fast results are the first target. “So we start with air leak detection and repairs, saving up to a staggering 43 kW on a 1 cm leak at 7 bar,” advises Prinsloo. Losses in energy consumption of as much as 20% can be quickly remedied with a simple repair using Atlas Copco’s RePress.

The automation of equipment control is also a focus and the company advises use of its monitoring and control technologies. Atlas Copco’s master controller, Optimizer 4.0, aims to ensure optimum compressor energy performance and minimised CO₂ emissions, with the added benefit of maximum local and online connectivity. The solution is designed to equalise running hours and lower the pressure band, reducing energy consumption.

Atlas Copco’s Energy Recovery solutions can also be implemented to further improve efficiencies.  Ninety-four percent of the energy consumed by an air compressor is converted into heat and a large portion of this thermal energy can be recovered for re-use in a variety of applications such as heating the workspace, providing hot water for industrial processes that require heat or steam, or for use in bathrooms. Prinsloo points to the substantial cost saving implications as a plant can scale down or eliminate the use of heat generating equipment such as geysers and preheaters for boiler water thus lowering overall energy consumption, while also reducing emissions.

Another solution from Atlas Copco is AIRnet, an aluminium and stainless-steel pipe range that is designed to provide optimal conditions so that high quality compressed air reaches the point of use with the right pressure and flow. The anti-corrosive, rust-proof properties of aluminium make it the industry standard for compressed air piping systems, ensuring less pressure drop and subsequently optimising air quality. The company asserts that its piping systems are compliant with the highest quality standards  ensuring 100% oil-free air delivery from generation to point-of-use, which is ideal for harsh environments like pharma and food and beverage. AIRnet is designed to be lightweight, safe, easy to handle and quick to install.

SmartLink is the company’s monitoring and communication system, that is used to monitor and self-diagnoses Atlas Copco machines and automatically upload data to servers in the cloud. SmartLink tracks all the vital signs of the compressed air equipment and can actively monitor more than 30 data points. Alerts can be sent to smart devices. The solution generates customised reports and recommendations that enable users to follow up on the performance and service status of all the equipment in the air compressor room, helping to boost overall machine health.

Service Timeline is an additional solution that indicates the service status of every machine and provides a calendar of planned visits as well as service reports. On-time service and predictive maintenance maximises uptime by enhancing machine reliability and stability. SmartLink Uptime is designed to monitor critical components with service, sensor and alarm data uploaded from the compressor every 40 seconds. Should an issue arise, users as well as Atlas Copco are immediately alerted and technicians are dispatched, helping to avoid costly unscheduled downtime.