Training Cycle: Optimise the energy efficiency and reliability of your compressed air systems
Compressed air machines are the perfect installation with a high energy-saving potential. A comparative study by Enprove showed that the savings potential of a compressed air installation (100kW/h, when running continuously) can easily amount to €150,000 per year. This equates to 1250 MWh or 500 tonnes of CO2. This is the equivalent of the electricity consumption of almost 300 families.
After this training cycle, you will be able to effectively realise these savings in your company.
The training cycle provides a theoretical framework about compressed air systems but is also very practical. At the end of the series, every participant has an assessment and improvement plan for their own compressed air installation.
Learning objectives
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Theoretical basics of compressed air and the impact on energy consumption
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Different types of compressors
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The importance of compressor maintenance
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How to best carry out measurements and how to detect losses through measurements
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Insights and tips to increase the energy efficiency of compressed air installations.
Programma
The training cycle takes 6 half-days. The sessions are guided by the energy specialists of Enprove. In addition, for each session a guest speaker from the field is invited.
You can follow the complete cycle or choose which sessions you want to attend.
Session 1: Introduction to compressed air and energy
In this session, the student receives the basic principles of compressed air and energy.
We discuss how you can control your energy consumption in general. The following topics are covered:
- Why is working on energy important? And how much can it yield?
- The basis of energy management
- The basis of investment decisions: from idea to IRR
- Theoretical principles of compressed air compression
- The operation of a compressor
- Electricity in compressed air production
- The operation of electric motors
- Thermodynamics in compressed air production
- Properties of (compressed) air.
Session 2: Compressor types, the distribution network and air quality
This session will take a closer look at the different types of compressors, and how they work. Depending on the needs of a company, a different type or brand will be chosen.
The following topics will be discussed:
- What are the different components of a compressed air system?
- Which types of compressors are available on the market, and when to choose which type?
- What does the control of a compressor consist of?
- The other components of a compressed air system are also discussed: dryers, filters, buffer vessels, etc.
Atelier Francois (Laurent Teughels) provides information on the operation of oil-free rotary vane compressors, and how they can be compared to screw compressors.
Tamturbo (Brecht Vanlee) gives a presentation on turbo-compressors and when they are best used.
Session 3: Measuring compressed air
This session is about measuring compressed air systems. Why is it best to measure? How do you do it, and which parameters are best to follow?
Then, the practice of measuring is also discussed.
The topics that will be discussed are:
- Why is it important to measure? What do you measure and what not?
- The different components of an energy monitoring system
- Types of meters
- A number of cases are discussed in which one could determine the savings by means of measurements
- Choosing smart KPIs
- How can you manage alarms and make sure that you are notified of energy losses at the right time?
VP Instruments (Sjim Janssens) will speak about compressed air flow meters and their physical functioning.
Endress + Hauser (Jean-Jacques Renaux) will explain the different types of sensors and their advantages and disadvantages.
Session 4: Energy efficiency
In this session, participants will learn much more about how energy savings can be realised and calculated.
We extend this to a higher level and look at how the monitoring of compressed air fits into an energy care system. The energy legislation and the subsidies that apply to compressed air are also mapped out.
In addition, Enprove carried out a benchmarking exercise on various compressed air compressors and reports the results.
Topics covered in this session
- Energy efficiency in compressed air systems: what can you do, and how much does it yield?
- The Compressed Air Benchmark results will be discussed
- Compressed air within energy care
- Compressed air within energy legislation
- Subsidies for compressed air related measures
- Case study compressed air optimisation at Lawter
SDT Leak Detection (Ronny Jacobs) will speak about ultrasonic devices to detect compressed air leaks.
Session 5: Compressor maintenance
In this session, the maintenance of compressors is discussed. Which activities does maintenance consist of? Who should carry it out?
We will also discuss the different types of maintenance contracts, and their advantages and disadvantages.
Topics to be covered:
- What are the most important maintenance activities
- What belongs in the contract?
- What types of contracts are there?
- The cost of a maintenance contract
- Common problems on compressors
- How does wear occur and how do you diagnose it
- Maintenance of dryers
Gianni Vanneste presents a case on the replacement of a large compressed air compressor at Puratos, and the elements that played a role in the investment decision.
Atlas Copco (Bart Eggermont) explains how they approach the maintenance activities.
Session 6: Feedback session
- Presentation of improvement cases to team of organisers and guest speakers
Awarding of training certificates
Closing drink for participants
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Sessions within this trajectory
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