The sector is turning the energy screw

German industrial entrepreneurs are committed to energy efficiency: According to a survey by dena, three-quarters of all industrial operations have carried out measures in the past two years to reduce their power consumption – more than ever before. Large companies with over 250 employees and high energy costs (€400,000 plus per year) in particular are focusing on this issue: Over 90 percent of them are already implementing corresponding projects. "The main focus is on auxiliary processes," says Annegret-Cl. Agricola, Head of dena's Energy Systems and Energy Services Division. These consist primarily of lighting, heating and cooling, and compressed air.

Energy and resource efficiency is a theme that runs through HANNOVER MESSE 2017. At ComVac, leading providers demonstrate how users can take advantage of major potential savings using innovative compressed air and vacuum systems – such as electronic speed control, rotary screw and piston compressors, and waste heat recovery.

The future is "quiet, efficient and smart."

BOGE KOMPRESSOREN is appearing in Hall 26 under the motto “Designed to take the lead.” One highlight at Stand B 56 is the S-4 Optimus rotary screw compressor. As an engineering study, the machine aims to show what a "quiet, efficient and smart" future will look like. The S-4 Optimus is a refinement of the S-4 series and a product "that is in advance of current technological standards," as Boge describes it. With 75 kW, the S-4 Optimus prototype will be showcased at the stand. The machine is the first stage in a new series that will be "even more dependable, energy efficient, and smarter in terms of controlling than other commercially available systems," says Thorsten Meier, Managing Director of Boge Kompressoren.

In Hall 27, Kaeser Kompressoren (Stand E 18) among others will be focusing on energy efficiency. "An efficient compressed air supply begins with efficient components," explains the company. That is why it has recently begun equipping all of its rotary screw compressors from 30 kW on up with Super Premium Efficiency IE4 motors. According to Kaeser, they have the best efficiency values and serve to reduce compressor power consumption even more.

Moreover, further refinement of Kaeser's airends – the key components actually responsible for producing the compressed air – has helped boost specific power by as much as 12 percent. "The new DSD and FSD series rotary screw compressors therefore offer significantly enhanced efficiency and higher flow rates – which translate into tangible energy cost savings," says the company. Its frequency-controlled ASD compressor series has set yet another milestone: The synchronous reluctance motor now installed as standard for the first time features markedly lowers rotor power losses – precisely in the crucial partial-load range – compared to asynchronous motors.

The silver bullet is efficient compressor management.

Atlas Copco is also bringing innovative rotary screw compressors to ComVac. According to the manufacturer, the compressors from its GA 90+-160+ / GA 110-160 VSD series are "efficient, reliable and durable, and developed for generating high-quality compressed air even under difficult conditions." Features such as variable speed control and energy recovery provide considerable cost and energy savings. The "newest generation of oil injected rotary screw elements" also provides "long life spans and trouble-free operation at low operating costs" even at ambient temperatures of up to 55 °C and in extremely rough environmental conditions according to Atlas Copco.

"Efficient compressor management is the fastest way to save energy," says Atlas Copco. Reducing operating pressure by 1 bar (14.5 psi) creates direct energy savings of up to seven percent; an additional three percent can be created by reducing leaks. The superordinate ES Energy Saving System makes it possible to connect all compressors and dehydrators, reduce the total range of pressure, abolish the need for high operating pressure, and minimise energy consumption.

Energy efficiency is also an advantage of the new GHS VSD+ rotary screw vacuum pumps. By adjusting the vacuum supply by regulating the speed drive or desired pressure to match the demand for vacuum, it uses up to 50 percent less energy than unregulated systems. And there is yet another lever companies can use to their advantage: "By recovering and reusing heat from generating compressed air, you can continue to improve the overall efficiency of the compressed air system and reduce your company's power consumption in general," states Atlas Copco when promoting its ER heat recovery systems.