1. People who care Increasing Profit & Contributing to Global Sustainability (Reducing carbon footprint through effective compressed air management) Presented by Nick Hunt Sector Business Development Manager November 2010 The Automated Material Handling Systems Association

2. Agenda Introduction to Motivair Industrial energy Usage Improving Compressed Air Efficiency Summary

3. Part of the privately owned £ 100m Leach Lewis Group Leading independent compressed air management company in Europe National service provider Motivair

4. National Coverage Service Support Parts Distribution Engineers Waltham Cross Burntwood Brownhills Cumbernauld

5. Servicing & repair Flexible service plans Equipment and Installations 24/7 emergency support Consultancy & support services Parts and accessories Products & Services

6. Compressed Air and Industrial Energy Usage

7. Typical Compressed Air Installation Compressor Receiver Dryer Filter

8. Compressed Air Usage 10% of all industrial energy is used to power air compressors

9. Source: Guide 241, E.T.S.U., Best Practice Programme, Dept of the Environment A typical rotary screw compressor Whole life cost of ownership

10. Energy saving and Carbon Footprint Reduction Following a recent government-backed site survey of existing systems across ten sites, energy savings of around 35% were achieved Much of this could have been achieve beforehand with better compressed air management

11. LeakageMaintenance Pressure Control ?

12. Designing and operating a system at unnecessarily high pressures will waste energy and increase running costs Pressure: Energy Consumption Source: Guide 42, E.T.S.U., Best Practice Programme, Dept of the Environment

13. 4567891011 40 60 80 100 120 140450 350 300 250 200 Pressure (bar) Flow (l/s) Power (kW) Pressure: Energy Consumption Source: Guide 241, E.T.S.U., Best Practice Programme, Dept of the Environment Power Flow Constant flow Increasing pressure = more energy used

14. Control ?

15. Control: Energy Consumption Supplying an air main at high pressure than necessary is costly Basic cascade control of compressors won’t allow close pressure regulation Consider a multi-compressor system...

16. System Pressure (bar) Air Demand Control: Less Pressure Saves Energy 100% Required Pressure 7.0 8.5 9.0 9.5 8.0 7.5 Wasted Energy Over-pressure

17. Control: Variable Speed Drives Matches speed and power usage to air demand Drastically reduces energy costs during times when the compressor is not fully loaded Pressure remains steady

18. Control: Less Pressure Saves Energy System Pressure (bar) Air Demand 100% 7.0 8.5 9.0 9.5 8.0 7.5

19. Leakage ?

20. A survey of 47 typical UK industrial sites found that the average compressed air leakage rate was 18% of total demand Leakage: Energy Consumption Source: Guide 42, E.T.S.U., Best Practice Programme, Dept of the Environment

21. Leakage: Annual Cost 024681012 £30,000 £20,000 £10,000 £0 Hole Size (mm) Ann. Leakage Cost £5,000 £15,000 £25,000 £35,000 7.0 bar g 7p per kW/hr 8,000 hrs/yr o o

22. Leakage: Distribution System

23. Leakage: Leak Detection Specialist ultra sonic equipment can be used to detect leaks and tag locations Can be used to monitor pressurized systems regardless of the type of gas used

24. Maintenance ?

25. If a compressed air system is not correctly managed it will become inefficient leading to wasted energy and increased running costs Maintenance: Energy Consumption

26. Maintenance: Routine Servicing Regular servicing in accordance with manufacturer guidelines ■ Service every 2,000 hours ■ Motor & air end re-bearing after 20,000 hours Annual system audits, including leak detection Remote Monitoring can ensure maximum efficiency

27. Maintenance: Performance Monitoring System monitoring to ensure that it is operating correctly and efficiently

28. LeakageMaintenance Pressure Control ? Reduced pressure = reduced energy Increased control = reduced energy Reduced leakage = reduced energy Regular maintenance = reduced energy

29. People who care Thank you Any questions? To receive a copy of this presentation by e-mail, please leave me your business card