Industrial companies continue to take action to minimize their carbon emissions. Many businesses have been reducing their use of fossil fuels and switching to clean, renewable energy. But what role does compressed air play in all this?

Compressed air is a public facility that needs attention

Sami Uusi-Erkkila, CEO of SmartAir and Energy, points out that compressed air is an important utility, just like electricity, steam, running water and other utilities. However, compressed air is often wasted without regard to energy consumption or compressed air leakage.

“In many industrial Settings, compressed air is often the second largest utility after electricity in terms of energy use. Therefore, it is really important to take steps to minimize compressed air related emissions, “Uji-Erkkila said,” Some of the key factors to consider include the size of the compressed air system, the investment in equipment quality, and how the system is maintained.” For example, measurement plays a key role in both the supply and demand of compressed air.”

Uusi-Erkkila also wants to call attention to the important fact that efficient systems do not necessarily reduce energy consumption, which means a more holistic approach is needed.

Use compressed air as a public utility

Antti Viitanen, Vaisala product Manager, agrees that you need to consider the entire production process in order to reduce energy use based on fossil fuels.

“You should start with the natural resources you are using. However, if the energy that powers the compressed air system cannot be replaced with a clean alternative, you can still optimize factors related to the life cycle of the system, “he said.

Viitanen also lists some questions about compressed air systems for you to check yourself:

How is the electricity produced to power the compressed air system?

Have you scaled the system appropriately for your needs and planned accordingly?

Have you chosen a quality compressor and dryer with an integrated high quality dew point meter?

Are you operating the system at the right pressure level?

Do you have a state-based automatic control system?

Do you have a demand-driven compressed air management system?

Do you make data-driven decisions based on existing data?

Do you find problems by following in regularly?

Can you recover and use the waste heat generated by your system?

Do you maintain the system regularly?

Have you provided training to operators on how to operate the system safely and efficiently?

Are you discussing further development with the sustainability team?

Compressed air quality has multiple meanings, as does humidity

Uusi-Erkkila explains that to solve even an isolated challenge, such as the problem of moisture in compressed air, there are many different things to consider:

“Most people who deal with compressed air know that moisture in compressed air systems is harmful. However, there are several reasons for the need to dry compressed air. We usually focus on the equipment that uses compressed air and its functions, but it is just as important, if not more important, to pay attention to the operating state of the compressed air handling equipment. If the location of the compressed air system has humidity sensitive components or functions, this may be a quick solution at a small cost. But imagine a situation where the entire drying process of the compressed air handling system runs at reduced power or fails. This situation affects all compressed air functions in the plant, whether it is a single compressed air gun or a particularly sensitive compressed air measurement sensor. Depending on the industry and the size of the company, there may be dozens or even hundreds of different compressed air users. That’s why it’s crucial to tackle the problem at its source.”

Uusi-Erkkila believes that the green transition to compressed air means that all activities strive to systematically reduce energy use, improve energy efficiency and minimize waste.

“Waste can mean compressed air leaks, excessive drying due to a drying system failure, or wasted opportunities for a compressed air training culture within a company.” When choosing a solution, you should take care to choose the right measuring instrument for your process, whether it is an adsorption dryer or a compressed air system that requires on-site sampling, “concludes Uusi-Erkkila.

Dew point measurement is an important part of the green transition of compressed air

Viitanen points out that dew point measurement is one of the main ways to save energy in compressed air systems and is therefore an important part of the green transition.

“Dew point measurement allows you to optimize the drying process of compressed air and avoid excessive drying. An optimized process with integrated dew point meters can significantly reduce the total cost throughout the year. With a hand-held dew point meter, you can also perform daily checks on compressed air humidity levels in almost any part of the production line. This not only prevents water leaks, but also allows you to take action before the quality of your final product is negatively impacted.”