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 systems, and a significant portion of their energy consumption is converted into heat during the compression process. Without heat recovery systems, this heat is typically lost to the atmosphere, wasting valuable energy. By capturing and repurposing this heat, you can significantly improve energy efficiency while reducing expenses and emissions.
Heat is generated as a byproduct of the air compression process at several points in your compressed air system. For example, oil-injected compressors use oil to cool the compression chamber and lubricate the moving parts to prevent wear and tear. The heat is transferred to the oil, which is then passed through an oil cooler to remove the excess heat. Without a recovery system, this heat is simply wasted but can be captured and reused.
Similarly, aftercoolers can be a major source of heat loss. Once the air in your system is compressed, it is typically too hot to use. An aftercooler releases this hot air, and this heat can be recovered.
As mentioned above, expertly designed and installed Atlas Copco recovery solutions can help you reclaim up to 94% of the heat produced, and this recaptured energy can be utilised in various ways.
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
Heat recovery systems can bring numerous advantages to your business for your finances, workplace efficiency, and the environment. The key benefits of our advanced Atlas Copco systems include:
Cost Savings
Heat recovery solutions can potentially shave a significant sum off your energy bills. By using the heat generated by your compressor to heat your facility and produce hot water, you can reduce your total energy consumption by up to 15%. Your heat recovery solution will likely pay for itself in no time. This makes them a low-risk, high-reward investment for energy-intensive facilities.
Minimised Environmental Impact
By reusing what would have been wasted heat, you can reduce your reliance on fossil fuels and external energy suppliers with fluctuating prices. Heat recovery systems can also reduce C02 emissions, help you meet your sustainability goals, and remain compliant with ever-changing regulations.
Improved Operational Efficiency
Heat recovery systems manage the heat produced during air compression, effectively removing excess heat from the compressor. This prevents overheating while optimising efficiency. Moreover, compressors that operate at stable temperatures are less prone to wear and tear, which means a heat recovery system can extend the lifespan of your valuable industrial equipment.
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.