While compressed air is critical for essentially any manufacturing or processing operation, the utility is also the largest consumer of a plant’s energy. Subsequently, garnering energy savings during the air compression process will irrefutably procure economic and environmental value-add for customers.
A staggering 94% of the energy that is consumed by an air compressor is converted into heat. This inexorable by-product of compressed air production is lost into the atmosphere via the cooling system and radiation. Atlas Copco once again demonstrates its well-earned reputation as an environmentally conscious, forward-thinking innovator, with the design of an energy recovery system. The unit smartly recovers all this wasted heat, transferring it to other areas in the plant where it can be re-used for multiple applications, essentially closing the loop.
“With our ER 90-900 energy recovery systems, operators are able to re-use this thermal energy, for example, to supply hot water in bathroom and kitchen areas or to heat work and office areas, addressing employee sanitation and comfort,” says JC Lombard, Business Line Manager for the Oil-free Air Division of Atlas Copco Compressor Technique. “Reducing a plant’s overall energy consumption will shrink both the electricity bill as well as the CO² footprint of the utility room, delivering financial and green benefits to the business.”
Lombard further highlights the fact that this thermal energy is also particularly suitable for process applications. He explains: “The hot water can be used as boiler pre-feed or even directly in industrial processes requiring temperatures of between 70°C to 90°C, providing a significant saving on costly energy sources such as natural gas and heating oil. This essentially means that operators can scale down or even completely eliminate boilers and other equipment required to generate heat or steam for industrial processes, thereby further adding to the bottom line for business sustainability.”
Available up to 900kW, the ER 90-900 energy recovery systems can be used together with Atlas Copco’s GA oil-injected and water-cooled, oil-free air compressors. These standalone, compact, small-footprint energy recovery units are specially designed by Atlas Copco for easy installation, operation, and maintenance. A dedicated connection kit further simplifies the installation process without affecting the compressor’s serviceability. The systems are available with either stainless steel or cost-effective copper coolers, depending on the application.
The value of investing in an Atlas Copco energy recovery system reaches even further. In addition to improving business profitability, the reclamation of a large portion of the free heat created by their air compressors, will assist operators to sustainably comply with increasingly stringent environmental compliancy standards.
Based on the compressor set-up, Atlas Copco’s highly skilled technicians, using an energy saving potential calculator, are able to indicate how much waste heat can be recovered and how much customers can save on their total energy bill. “Armed with up-front knowledge of the savings they stand to realise, customers can install an energy recovery unit with confidence and include these calculations in their business plans and profitability projections,” concludes Lombard.
