Efficiency

Modern, energy efficient compressed air systems, as well as individual analysis of compressor systems, can bring about potential energy savings of 30 to 50 percent. The entire lifecycle of a compressed air system is much more than simply the initial expenditure – energy costs make up 75 to 90 percent of total costs. By exploiting the available opportunities to improve the efficiency of your compressed air systems, you can ensure lower long-term expenses, with a return on investment achieved quickly given the aforementioned cost structure. Improving energy efficiency is not only cost-effective, but also responsible helping to preserve our environment.
 

Energy-efficient compressed air – good for your wallet and the environment

Far too often, the huge savings offered by efficient compressed air generation are not fully exploited.

Efficient compressed air: reducing energy consumption by up to 50 percent

In a typical industrial plant flow, just 45 percent of the total energy use for the compressed air system goes into satisfying the actual amount of compressed air demanded. That means that up to 55 percent of the energy is typically wasted. The main causes of these cost-increasing problems in compressed air systems are leaks, unnecessary supercharging or improper usage. But with some easy alterations, the energy needs of the compressed air supply can, in many cases, be reduced by 30 to 50 percent – which also makes them much more efficient. For example, in 8 out of 10 compressor systems, you can save around 20 percent of energy consumption alone through the reduction of leakage losses. To further increase energy efficiency, you should first make a thorough analysis of your compressed air situation – we'll be happy to help you so do get in touch

 

Energy costs contribute up to 90 percent of total costs

By exploiting potential savings, you can make a positive and lasting economic change for your company. At 75 to 90 percent of the total expenditure, energy costs are the lion’s share of the total costs over the entire lifecycle of a compressed air system, and are significantly higher than the original purchase cost. A simple rule of thumb is this: the larger the plant and the longer the hours of operation, the greater the amount of energy costs in the total cost. By investing in highly efficient BOGE products, you can reduce long-term costs.

 

Energy-efficient compressed air helps protect the environment

Using energy efficient compressed air, not only reduces your long-term costs; it also helps you to play your part in trying to reduce climate change. The annual energy consumption of Germany's 62,000 compressed air stations is currently around 14 billion kWh – roughly the same as 1.5 nuclear power plants. That figure could be cut in half by changing to modern, properly operated compressed air systems.

A step-by-step guide to improved compressed air efficiency

Efficient operation of compressed air systems can be achieved by simple, tangible steps. To start, we can create a cost-benefit calculation for you.

1. Demand analysis and leakage measurement

Looking only at the energy demands of your compressors rather than their leaks has a significant negative impact on energy consumption. Reducing these leaks offer the greatest potential for savings. To achieve these savings, the optimal running of the compressors must be determined, based on demand analysis and regular leakage measurements. Contact us to have a reliable and effective analysis carried out.

 

2. System design

Efficiently operating individual components is just the first step in making energy savings. The optimal interaction of these components and the alignment of the entire system to your specific needs can have a positive effect too. With an intelligent design of the process chain, you can optimise your energy and resources.  At BOGE, we are the seasoned professionals in this field, with years of expertise behind us. Contact us for advice and recommendations.

 

3. System Renewal

With compressed air systems that are starting to feel their years, a complete overhaul can be worthwhile. This depends on the technical state of your system and how much of the energy it uses is converted into the final desired performance. These days, modern compressors are equipped with high-efficiency motors and airends, with modern fans and heat recovery. The investment in a new plant can quickly pay for itself, while these sorts of investments are becoming increasingly supported by the government.

 

4. Intelligent control systems

An optimal ratio for load and idle times can be achieved by the use of intelligent control systems. These control systems select the most efficient air compressor combination according to demand. This allows you to keep the idle time and the pressure at an optimum level at any time. In addition, the parameters of your system become more apparent.

 

5. Heat Recovery

During the air compression process a high percentage of energy is converted into heat. Modern and efficient air compressor systems ensure that this energy is not wasted. Up to 94 percent of the heat generated in the compressor can be recovered. It can then be routed to a suitable part of your company’s premises or used in the form of hot water.

Intelligent control

Get intelligent compressed air with our airtelligence family. With airtelligence plus, you can control up to six compressors – even ones of different types. With airtelligence provis, you can control up to 16 compressors and 24 other accessories.

 

Benefit from easy to use, intelligent, automatic compressed air management, as well as high efficiency.

 

airtelligence plus

Our airtelligence plus control is your easy path to efficient compressed air. With it, you can control up to six compressors in the network. With a cyclic base load, uniform utilisation of all compressors is possible. You benefit from reduced maintenance costs and increased profitability. airtelligence is...

  • Easy to read, thanks to its 4-inch LCD colour display
  • East to use, thanks to its user-friendly and intuitive operation
  • Efficient, thanks to its balanced use of all connected compressors
  • Flexible, thanks to its connection of identical or different (ever older) compressors

 

airtelligence provis 2.0

Compressed air control made easy. With airtelligence provis 2.0, you can control up to 16 compressors and up to 24 accessories – such as dryers, condensate separators or filters – in the network. As required, you can choose between independent, rigid or variable frequency controls. The intelligently designed airtelligence provis 2.0 allows you to create highly efficient compressed air easily:

  •  Intuitive operation, thanks to its 9-inch colour display with touch pad
  •  An intelligent consumption-based control of all connected compressors, thanks to its automatic selection of the optimal compressor combination
  •  Flexible management of complex air systems, thanks to its unique combination of available status values
  •  A clear overview of all important data – such as the volume flow of the compressor status or dewpoint – thanks to its browser-based visualisation.

 

Optionally, you can also upgrade to Pro visualisation. This gives you additional alarm management, as well as remote monitoring with analysis and subsequent evaluation of the data via data export.

High efficiency premium products – save money and energy

Purchasing high-quality compressed air products with the highest efficiency values possible pays dividends in energy savings in the long term.

For all components, you can trust BOGE quality. Low-quality components lead to increased and inefficient energy consumption, a reduced service life and frequent maintenance intervals. Our highly efficient BOGE effilence airend and BOGE S Series machines and motors, rated in the highest efficiency IE3 or IE4 classes, quickly bring a return on compressed air investment.

 

SLF machines: Responding quickly to fluctuating compressed air demands

If you want to react very quickly to highly fluctuating compressed air demands, our frequency control-fitted SLF machines are the right solution. Constant control of the motor speed allows you to change the delivery quantity of the air compressor. The energy saving mode is extremely advantageous for both low storage volumes or during peak load operation.

 

The premium BOGE effilence airend

Our airend ensures silky smooth operating, with an optimal design of power ranges, low power losses and high volume efficiency. This is made possible by the 5:6 screw profile of the rotors – specially developed by BOGE engineers – which leads to a lower pressure differential between the chambers. The rotation speed is also optimally designed. Efficiency losses due to splashing are reduced, the levels are quieter and their lifecycle is extended. Thanks to these properties, the effilence is the most efficient airend we’ve ever created.

 

BOGE S-Series

With the BOGE S-Series, we concentrated on developing highly efficient components that meet the latest requirements. Incorporated into the S-Series are: the highly efficient effilence airend, the Premium Efficiency IE3 class motor (or the Super Premium IE4 class motor), the latest generation focus control management system and an optional fan with frequency converter. Thanks to these high-quality components in our S-Series, you can save energy in the overall system by up to 35 percent.

 

BOGE IE3 and IE4 motors: A quick return on investment through energy efficiency

Efficient electric motors are an essential part of an energy-efficient compressed air operation. About 90 percent of the total cost of an electric motor over its lifetime is in its power consumption. The investment therefore pays for itself quickly. In our machines, we use the S-Series with a Premium Efficiency IE3 class motor as standard. If desired, you can also have the highest class currently available, the Super Premium IE4 motor.