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Everything you need to know about compressed air monitoring equipment

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Year after year, companies search for more and more efficient systems, allowing them to save money and energy. In Ceccato Aria Compressa, offering efficient air compressors is at the top of the list. Being made up of more machines, there are several ways to save money and energy from a compressed air installation. The main are:

  • Energy recovery system for heat coming from compression.
  • Monitoring systems.

Energy recovery for compressed air savings

Reusing heat is a way to make your compressed air system more efficient and energetic optimised. The compression process generates heat that can be re-used to warm other rooms, facilities and machines.

From the total heat of the compression process, 10% is inevitably lost. The rest 90% is available for recovery. When using hot water as boiler pre-feed or directly in process requiring it can save expensive energy sources, such as natural gas and heating oil.

Hot water recovered from the compressed air system can be used for:

  • Auxiliary or main heating of warehouses and workshops.
  • Industrial process heating.
  • Water heating for laundries, industrial cleaning and sanitary facilities.
  • Canteens and large kitchens.
  • Chemical and pharmaceutical industries.
  • Drying processes.

How energy recovery works and applies to savings

Most of the energy used in the compression process turns into heat. The greatest amount of the oil-injected compressor’s compression heat is dissipated through the oil system.

Energy recovery systems re-use most of this heat, turning it into warm or hot water, avoiding any effect on the compressor’s performance.

The energy recovery system removes the heat of compression using oil injection. The oil is cooled in coolers and flows in thermostatic valves: in this way, reliable compressor operation and optimum energy recovery have been ensured. These valves guarantee the compressor’s reliability and excellent energy recovery. The energy recovery utilizes the compression’s heat to warm up cooling water.

Optimise your energy consumption with ECOntrol6

Energy consumption can represent more than 70% of a compressor’s lifecycle costs. Therefore, your compressed air system must be controlled properly. It can result in various advantages: from energy saving to decreased downtime, reduced maintenance and improved product’s quality.

To boost energy efficiency with a complete compressed air system, Ceccato Aria Compressa offers a specific monitoring system: ECOntrol6. The improved monitoring system highlights compressed air needs of your production system and matches it with a specific supply. With ECOntrol6 you're going to improve your compressed air savings.

Optimising energy consumption with ECOntrol6 provides several benefits:

  • Improved overall performance of your compressed air system
  • Transparent and streamlined process
  • Air supply matches your specific energy consumption needs.

ECOntrol6 can monitor and regulate up to 6 air compressors and it keeps them working close to the optimum point. ECOntrol6 controls the air compressors’ motor speed, and, in case, it adjusts it by regulating each compressor every half second. This controller can be manually sequenced, allowing to include also old compressors to your compressed air installation.

The ECOntrol enables you to save according to your specific energy consumption working with two different pressure bands. If you know that for every 1 bar pressure reduction in a 7-8 bar(e) system, you reduce your energy consumption by 7%, it is clear that the ECOntrol considerably cuts your energy bill.

ECOntrol6 reduces maintenance costs and optimises the maintenance service schedule by balancing working hours across compressors. It allows the machines to work in groups and ensures that the running hours are equal for each air compressor in the same group.

Equalising all machines’ working hours, the ECOntrol6 allows your compressed air system to be more and more efficient: maintenance costs and services are drastically reduced as well as your compressed air energy consumption.

The ECOntrol6 allows to monitor your complete compressed air network online. The features include warning indications, compressor shutdown warnings and maintenance scheduling.

Besides, it spreads running hours across different compressors with the same priority and adds offset hours for new machines.

If connected to a compressor room, the ECOntrol6 provides an overview of the entire compressor room process.

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The ECOntrol6 allows to monitor your complete compressed air network online. The features include warning indications, compressor shutdown warnings and maintenance scheduling.

Besides, it spreads running hours across different compressors with the same priority and adds offset hours for new machines.

If connected to a compressor room, the ECOntrol6 provides an overview of the entire compressor room process.

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