Compressed air savings a priority

Pneumatics & Hydraulics

January 2006 Pneumatics & Hydraulics

We have all heard the bad news regarding the expected rise in energy cost. Now is the time to look for ways to conserve energy. Almost every industrial facility has at least one compressor that is used for hundreds of different tools, equipment and operations. Improper use can translate into unnecessary energy costs and high noise levels. Now is the time to start boosting efficiency.

The use of compressed air for blow off in most facilities is a problem due to the energy costs, noise level and potential danger to personnel exposed to the high pressure. Open air pipes, copper tubes and drilled pipes are a few of the common abusers. They consume huge amounts of energy and often produce noise levels over 100 dBA.

The best way to cut energy costs is through proper maintenance and use of the compressed air system. Leaks and dirty filters require maintenance on a regular basis. Energy savings can also be realised when replacing outdated compressor motors that often pay for themselves in a short period of time.

The most important factor to dramatically boost efficiency is proper use. Using engineered products like Exair's new Super Air Nozzle can cut operating costs since it uses only a fraction of the compressed air typical blow offs. In addition, all Exair jets and nozzles can be cycled on and off with instant response so the compressed air is only used when needed.

For example, a 1/8-inch open pipe blow off system at 550 kPa uses 2 m³ per minute. Replacing the open pipe with an Exair Adjustable Air Nozzle model 1009SS, will result in a reduction down to 0,37 m³ per minute at 550 kPa - a saving of 1,63 m³ per minute.

The air saved in this example is sufficient to run two Exair Panel Coolers (model 4030) to stop electronic downtime due to heat. These keep the electronics cool and simultaneously positively pressurise the panels, keeping them clean and dry, thus reducing maintenance and housekeeping costs. Further savings may be had by thermostatically controlling the panel cooler, so that it will only run when heat levels become critical, conserving air accordingly.

Often blowers are chosen over compressed air driven units due to their slightly better electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of filters, belts and bearings. Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required. Notwithstanding the fact that often water is not completely removed from the product and can backlash in the form of 'rust under bottle tops'.

All Exair equipment meets or exceeds OSHA requirements on noise and dead end pressure levels. Making it one of the safest, cost effective and efficient compressed air product ranges available.

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Pneumatics & Hydraulics

Compressed air savings a priority

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