Energy Recovery for Air Compressors
Compressed air systems play a vital role in almost all industries. Businesses often rely on air compressors to power tools, equipment, and machinery in manufacturing and industrial settings. However, compressed air systems are prevalent in many environments, from powering HVAC systems in large commercial buildings to supplying air to medical apparatus in hospitals.
Unfortunately, while compressed air systems bring a host of benefits and practical uses to countless industries, they are energy-intensive. In fact, up to 94% of the electrical energy consumed by an air compressor is converted into heat. Without a heat recovery solution, that energy is simply wasted, which can make your air compressor highly inefficient, costly to use, and damaging to the environment.
Thankfully, heat recovery solutions manufactured by leading brands like Atlas Copco can recover up to 94% of the heat that your compressor would otherwise waste. You can use that recovered energy to heat the interior of your workplace or generate hot water. In some cases, heat recovery can account for up to 70% of a company’s heating requirements, resulting in up to 20% overall energy savings.
At Search Air, we have been a leading supplier and installer of compressed air systems and accessories for over 75 years. We have proudly been a premier distributor for Atlas Copco since 2001 and were named Atlas Copco Compressors Distributor of the Year in 2022. Below, we will explain everything you need to know about heat recovery systems and how they can benefit your business. If you have specific questions about your unique situation, please call us.
Understanding Energy Recovery in Air Compressors
Air compressors are energy-intensive, with a large proportion of the energy supplied to the system converted into heat during compression. Without an air compressor heat recovery system, this valuable energy is simply lost, increasing operational costs and environmental impact.
Heat is generated throughout the compression process. In oil-injected compressors, for example, oil absorbs the heat and passes it through an oil cooler. Similarly, aftercoolers lower the air temperature by releasing more waste heat via hot air. Without an energy recovery system, both sources contribute to unnecessary waste.
This recovered heat energy can be captured and repurposed using heat recovery solutions. Modern air compressors allow waste heat recovery either via hot air for space heating or through hot water generation using a heat exchanger. In many cases, up to 94% of the available energy is recovered and reused.
The quantity of recovered energy will vary depending on factors such as compressor design, whether the compressor has a variable load, and whether there is a stable heat energy demand within the facility. For businesses with consistent requirements, the investment for energy recovery can often pay back within two to three years.
By integrating an air compressor energy recovery solution, companies can significantly reduce energy consumption, cut carbon emissions, and better use the heat already produced – without disrupting day-to-day operations.
Energy Recovery for Air Compressors
Types of Heat Recovery Systems
There are many ways in which recovered heat from an air compressor can be repurposed to prevent unnecessary waste and environmental damage. Hot air utilisation and hot water generation are the two primary types of heat recovery systems in most industrial and commercial settings.
Hot Air Utilisation
In many workplaces, the most cost-effective and straightforward heat recovery system is hot air utilisation, which essentially allows you to redirect the recaptured hot air into areas requiring heating. Instead of allowing your system’s aftercooler to expel the hot air into the atmosphere, we can install ducting systems that channel the hot air to specific areas of your workplace or industrial facility. In some cases, this redirected hot air can account for well over 50% of a business’s overall heating needs.
Hot Water Generation
Hot water generation is a more advanced form of heat recovery. While these solutions can be more expensive to purchase and install than hot air utilisation systems, they are often more versatile and beneficial in the long run in industrial settings. These hot water generation systems work through heat exchangers installed in your compressor’s cooling unit.
The heat from the oil or cooling water, which has absorbed energy from the compression process, is transferred to clean water via the heat exchanger. Depending on the system design and compressor type, the resulting hot water can reach temperatures up to 90°C.
How water generation systems boast a wide range of commercial and industrial uses, including:
- Cleaning and sanitation
- Process heating
- Central heating
- Boiler feed water
- Industrial washers and equipment
Benefits of Implementing Heat Recovery Systems
Introducing an energy recovery system into your compressed air installation can bring a range of advantages, delivering both immediate and long-term value across financial, operational, and environmental fronts.
Cost Savings
Using heat recovery significantly reduces the need for separate heating sources. By capturing the waste heat energy generated during compression, you can provide hot air for space heating or generate hot water for cleaning, process operations, or central heating. This recovered heat energy can account for up to 70% of your facility’s heating requirements, cutting overall energy consumption by as much as 15–20%. In most cases, businesses see a return on investment for energy recovery within two to three years, making it a low-risk, high-value upgrade.
Minimised Environmental Impact
Heat recovery systems play a vital role in reducing energy consumption and lowering carbon emissions. Instead of relying solely on fossil fuels or external energy supplies, businesses can use waste heat recovery to supplement energy needs sustainably. This helps companies meet stricter environmental regulations, improve sustainability reporting, and contribute towards corporate net-zero goals, while also reducing vulnerability to rising energy costs.
Improved Operational Efficiency
Recovering heat from your compressed air production improves overall system stability. Heat recovery systems help maintain optimum operating temperatures by removing excess heat from compressors, reducing the risk of overheating and the wear and tear associated with temperature fluctuations. Equipment that operates within a stable temperature range typically lasts longer, offers better performance, and requires less maintenance — all of which translates to cost savings further and reduced downtime.
Enhanced Workplace Comfort and Versatility
Energy recovered from compressed air can be used flexibly across your site. Whether you need hot air for space heating, hot water for process applications, or a combination of both, modern air compressor heat recovery systems provide a practical and adaptable solution. Some systems even allow for automatic switching between heating modes, maximising the use of available energy all year round.
Stronger Business Resilience
Integrating waste heat recovery into your compressed air system makes your business less dependent on external energy supplies. In industries where energy prices are volatile, using heat recovery offers greater control over operational costs and shields businesses from sudden market changes, supporting long-term resilience.
Learn More about Heat Recovery Systems for Air Compressors
As you can tell from the above, heat recovery solutions have the potential to bring a range of significant benefits to your business. In fact, our systems contribute much more than just individual business benefits – they could save 1.99% of the total industrial electricity consumption in the UK.
If you want to know exactly how an Atlas Copco system can help your business, do not hesitate to call us. We are an award-winning supplier and installer of advanced solutions with over 75 years of experience. You can feel confident that you are in safe hands when you trust Search Air.
FAQs
What is an air compressor heat recovery system?
An air compressor heat recovery system captures the heat generated during compression and repurposes it for practical use, such as space heating or hot water production. Without a recovery system in place, this valuable energy would otherwise be wasted, increasing energy consumption and costs.
How does using heat recovery benefit my business?
Using heat recovery helps reduce energy bills, lower carbon emissions, and improve overall operational efficiency. By recovering waste heat energy from your compressed air installation, you can supplement your heating needs, cut reliance on external energy sources, and extend the lifespan of your equipment.
Can a heat recovery system be added to existing compressors?
Yes, a modern energy recovery system can often be integrated into an existing compressed air installation. Whether you are using oil-injected or oil-free compressors, there are solutions available to recover waste heat via hot air or hot water, helping to reduce energy consumption without major disruption to your operations.