Introduction: Welcome to a new era of sustainable industrial practices! At Coolair Compressors we believe in harnessing the power of innovation to create a greener, more efficient future. Our commitment to sustainability extends to every aspect of our business, and we’re excited to introduce you to the game-changing world of Sustainable Compressed Air Systems.

The Challenge: Traditional industrial processes often overlook the environmental impact of their operations. Conventional energy sources, high maintenance costs, and inefficiencies have long been the norm. It’s time to break free from this cycle and embrace a more sustainable approach.

The Solution: Enter compressed air systems—the unsung heroes of sustainability in industrial settings. By optimizing and upgrading your compressed air infrastructure, you can achieve remarkable improvements in energy efficiency, cost savings, and overall environmental impact.

Energy Savings In Compressors:

Energy Efficiency: Compressed air systems, when designed and maintained properly, offer unparalleled energy efficiency. By minimizing air leaks, optimizing pressure levels, and investing in energy-efficient compressors, you can significantly reduce your carbon footprint.

It is obvious that energy prices are very high today. Energy prices are high not only in our country but in many parts of the world.

Energy reduction measures and processes are of great importance for the continuity of production, user benefits and environmental conditions.

80% of the life cycle cost of compressors is energy cost. Therefore, steps and precautions to be taken for energy saving will make it possible to achieve huge savings compared to both first aid cost and maintenance costs.

The items that will save energy in compressors are listed below:

1-Prevent leaks:

Compressed air system leaks can be 30% most of the time, 20% on average. This is a huge energy loss. Compressed air is directly released into the atmosphere from leaks. For example; the compressed air flow rate lost from a 2 mm hole at 6 bar is 0.240 m³/min and the corresponding energy loss is 1.7 kW.

Nowadays, there are various devices developed to detect leaks in compressed air installations. There are devices that only find the location of the leak, and in addition to this, there are devices that take a photo of the leak point and determine the approximate amount of leak according to the exit speed. Connection points are especially the points where leaks occur, and it is essential to check and correct these points.

2-Optimize environmental conditions:

The compressor room should be clean, free of dirt and dust and have a low humidity level; this will contribute to the compressed air dryer, filter, etc. being less loaded, having a longer life and saving energy. Controlling the temperature of the compressor room is an important process in terms of energy. Every 5 °C cooling provides 1.5% energy saving. (Since the air sucked from the hot environment will be lighter; more energy is required to obtain the desired flow rate.)

Depending on the season, it is very important to take the compressor suction air outside the compressor room and discharge the heated cooling air through a duct for compressor room optimization.

3-Optimize your working pressure:

It is very important to set the pressure required by the business on the compressor (taking into account the pressure drops of equipment such as installations, dryers, tanks). Because, in practical calculations, a pressure drop of 1 bar will provide approximately 7% energy savings. In order to optimize the operating pressure on the compressor;

a) Taking into account the pressure required by the business; the idle-load pressure band can be narrowed (can be set with a difference of 0.5, 0.7 bar).

b) By using a frequency converter, the target pressure set value can be adjusted to the pressure used by the business.

c) With the automation system; the system pressure is adjusted to a fixed value, taking into account the capacities of the compressors.

4-Optimize your compressed air installation:

One of the advantages of using compressed air is that it can be transported throughout the installations. If the compressed air installation is not optimized; pressure losses and energy losses occur during this transportation. What can be done for optimization:

If there are long installations, make a ring line to obtain the same pressure throughout the installation.

To minimize pressure drop, install a system with a suitable diameter. To calculate the system diameter; the system length, (considering the equivalent lengths of parts such as elbows, T’s) working pressure, flow rate can be easily calculated from the diagrams with the help of parameters. The maximum pressure drop caused by the system is usually taken as 0.1 bar.

Lay the installation with a certain slope (e.g. 1%) and install condensate drains at regular intervals.

5-Perform your compressor maintenance regularly:

It is important to perform compressor maintenance regularly and at the manufacturer’s recommended periods using original spare parts. These maintenance, which are recommended depending on time, are performed to prevent damage to the compressor unit by replacing deformed parts such as air filters, oil filters, and separators.

If you are using a compressor from a company that uses high-tech systems such as Sarmak Compressor; with the help of various sensors placed in sensitive areas of the compressor, you will be instantly aware of any limit exceedance, and (with the help of cloud technology, wherever you are in the world) you can intervene in the parts that require urgent intervention. Or; you can extend your maintenance periods and prevent unnecessary part replacement. In short, you provide proactive maintenance.

6-Use a heat recovery system:

In compressor technology, a significant portion of the energy is spent on heat during pressurization. In oil-injected Screw Compressors; approximately 75% of this heat remains in the oil. If you do not have a heat recovery system; this heat is released to the atmosphere using various cooling fans. Obtaining hot water by taking this heat from such a high-temperature oil means evaluating the heat that will be released to the atmosphere. Using compact, brazed exchangers, the heat in the oil can be used to heat water. Exchangers can be placed inside or outside the unit. The hot water flow rate that can be obtained can be calculated with the following formula: 

M: Hot water flow rate (kg/sn) E: Potential energy (75% of nominal power, kW) Cp: Specific heat of water = 4.18 kJ/kg °C: Heating degree of water

Join the sustainability revolution with Coolair Compressors. Upgrade your operations, save on costs, and make a positive impact on the planet. Embrace the power of compressed air systems—your gateway to a greener, more efficient tomorrow. Contact us today to embark on your journey toward sustainable success.

Sarmak Air Compressors offer high efficiency and outstanding savings in both energy and maintenance.