Optimising compressed air system management in the company

Control operating costs related to compressed air systems in the company

Compressed air is an energy carrier that is frequently used in many sectors, particularly in the use of production machinery and specific pneumatic tools. Despite its abundant use, it is a complex medium to control, resulting in high operating costs. In an unmonitored installation, losses during heat generation and distribution due to leaks can be up to 90 %. Compressed air costs can be contained by regularly analysing energy requirements and through technological monitoring. This measure is required for every new compressed air system.

Definition of compressed air requirements

Inspection of compressed air system

• Assessment of the existing compressed air system based on the “4-step guide to compressed air system optimization”

Re-evaluation of compressed air applications

• Given the very high cost of using compressed air, it is advisable before any optimisation to determine whether compressed air is the best way to perform this task.
• Reduce network pressure as far as possible according to compressed air requirements (temporary reduction possible depending on requirements) Identify and eliminate leaks in the existing system.

Implementation of compressed air optimisation measures

Control of compressed air system

• Minimize air leaks, plan regular checks, e.g. once a week, using the guide “Les fuites d’air comprimé vous coûtent cher”(Costly air leaks).
• Consider using a leak detector
• Regular maintenance
• Organise periodic inspections (to be carried out by an approved body).
• Optimise the installation with the conclusions of the inspection reports .

Setting the correct compressed air pressure level

Each compressed air consumer and compressor is designed to operate at a specific pressure. It’s a question of finding the right balance between production, the network (with its load losses) and the various consumers.

Implementation of best practices for compressed air system use

• Raising awareness among employees who use compressed air
• Adapt operating times to work schedules, e.g. overnight or weekend shutdowns, temporary shutdowns, etc.

Waste heat recovery:

Renewing the system is an ideal opportunity to check whether waste heat can be used. The heat recovered can be used to heat domestic hot water or premises. The use of waste heat with a heat exchanger is generally economical if the compressor size is 15 kW or larger. If conditions are ideal, heat recovery can also make sense with smaller compressors.

The following points should be clarified:

• Can waste heat from the compressed air system be used for warm-air heating in winter?
• Can you combine a heat exchanger with the installation (used to support heating, domestic hot water production or process heat)?
• Does it make economic sense to use waste heat?
• Can I remove waste heat from the compressor when it’s not in use (in summer)?
• Is the system still fit for purpose and efficient enough (installation of a new compressed air system)?

Subsidy application

Government subsidies

• SME Packages – Sustainability
  • Flat-rate €5,000 grant for small and medium-sized businesses for projects to reduce their environmental impact, costing between €6,650 and €25,000 excluding VAT.
  • For questions :
    • Chambre des Métiers for crafts industry
    • Chambre de Commerce for businesses in the non-craft sectors
      
• SME scheme – Consultancy subsidies
  • Support for small and medium-sized businesses, up to 50% of fees for external consultancy services
  • Verification of project eligibility and granting body: Ministry of the Economy (Department for Support to SMEs)
  • o For questions:
    • Chambre des Métiers (Chamber of Skilled Trades and Crafts)
    • Chambre de Commerce for businesses in the non-craft sectors

N.B. Government subsidies cannot be combined for the same project.

Assistance from electricity and natural gas suppliers for compressed air systems

Since 2015, natural gas and electricity suppliers have been obliged to deliver energy savings to consumers as part of the obligation mechanism. Since then, energy suppliers have been offering support and advisory services, as well as assistance programs for consumers to implement energy efficiency measures.

The following suppliers offer this service to businesses:

• Enoprimes Enovos + SUDenergie
• SUDenergie
• Sudstroum

N.B.: Subsidies from suppliers can be combined with state subsidies for the same project.