Cut the costs of compressed air!

Slide presentation:
Cutting costs of compressed air production

Compressed air is employed in a wide variety of scenarios as a versatile yet costly energy carrier. In its life cycle, energy costs of a compressed-air system sum up to 70 to 80 % of the total costs. For example, a medium-sized system (30 kW) creates yearly energy costs of around 10.000 €.

These costs can be slashed by leveraging the great optimization potential of a typical system - by simple and economic measures, e.g. by fixing leaks: ten miniscule leasks with a diameter of 1 mm would cause additional energy costs of 3500 € per year. These costs can be saved with little effort. However, being able to recognize leakages as soon as possible is a prerequisite.

deZem offers real-time monitoring and analysis of your compressed-air system. Even creeping pressure loss is recognized quickly and can be stalled before costs start to accrue. Our alerts by text message or email help support personnel to react promptly. Additionally, our characteristics and indices offer an optimal way to compare and improve the efficiency of different compressed-air systems: often the electric power per m³/h of compressors is as high as 130 W compared to the ideal 100 W.

Compressed air monitoring with mit deZem:

• Real-time monitoring of all relevant parameters: Nominal pressure, flow, electrical power of compressors etc.
• Alerts by text message or email upon violation of threshold values.
• Freely configurable characteristics and indices for analyzing compressed air systems and saving measures such as:
  • Reduction of nominal pressure
    (Machines typically need compressed air of only 6 bar. A reduction of nominal pressure - i.e. required pressure plus pressure loss due to filter and pipes of about 0,6 to 0,9 bar - reduces both power consumption and leakage loss. Additionally, it increases the life time of the compressor.)
  • Mending of leaks
  • Utilization of waste heat
    (A large percentage of compressor power - about 80 % - becomes "waste heat" at a valuable temperature level of around 80 °C).
  • Demand-driven production of compressed air, etc.

Example: energy consumption of a compressed air system reduced by 45%!

Equipment	Compressed-air system
Relative savings	45%
Total savings per year (assuming constant energy price)	83.000€
Pay-back period	<2 months
Measures	Removal of leakages, reduction of air pressure by 0,5 bar, frequency converter in front of air compressor screw