Process, Controls & Plant Focus on: Compressed Air 20 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 Compressed air is a proven source of reliable and sustainable power for industrial operations. Now, with technologies such as remote monitoring and AI optimisation, it is set to enter a new era of performance and efficiency. Where next for the fourth utility? Compressed air is often referred to as the fourth utility after water, gas, and electricity, underlining its essential role in various operations. It is a foundational technology in the industrial sector that powers a wide array of machinery, tools, and processes. Indeed, the global air compressor market is sizeable - and expanding fast. It was valued at over $27 billion in 20231 and is expected to reach $37.98 billion by 2030, growing at a Compound Annual Growth Rate of 4.76% from 2023 to 2030. Market growth is driven by various factors and trends, led primarily by a focus on energy efficiency and the continued expansion of the industrial sector, particularly in developing economies. Importantly, compressed air - as an overarching technology - never stands still. To retain a central role in the industrial sector, it needs constant refinement and evolution, offering end users new value-adding capabilities. This journey continues today, with emerging concepts such as digitalisation and the application of artificial intelligence bringing more advanced operations in the medium term. The application of compressed air systems So, what might that evolution look like? What are the latest cutting-edge innovations in the compressed air industry, and how might these transform industrial operations, enhancing efficiency, sustainability, and productivity across various sectors? To answer those questions, it is worth looking at how and why compressed air has secured such an important role in modern industrial settings. After all, in terms of application, compressed air is the silent partner to every industry imaginable. For instance, manufacturing uses it to run equipment and control process valves, and to power pneumatic tools such as air hammers, drills, and spray paint guns on production lines. It also helps with materials handling, moving products on conveyors and vacuum lifting them without damage. It is used for blasting and finishing, as well as heating and cooling. Yet this prevalence isn’t just found in the manufacturing sector: compressed air is also applied in medical, food processing and oil and gas applications, to name but a few. In short, it is a flexible, versatile and reliable energy source that can be used for various industrial applications. Taking a whole-life approach to system optimisation However, this ubiquity presents challenges. Air compressors account for as much as 12% of all industrial electricity usage, and energy consumption accounts for up to 70% of the lifecycle cost of a compressed air installation. Therefore, energy efficiency is critical and represents a key area of recent development. Subsequently, most compressed air suppliers recommend taking an end-to-end approach to compressed air management. This starts with having a full understanding of compressed air infrastructure by carrying out a comprehensive audit of installations over a significant period, including energy input, air flow demand, system pressure, air quality, pressure drops, and more. This forensic process helps identify potential savings and leads to suggested actions to achieve these cost efficiencies. Repair is also a critical consideration. Up to 20% of the energy consumption in a compressed air system can be lost to air leaks. These days, fixing leaks while the distribution net is under pressure and without dismantling pipes or couplings is possible. Then, by investing in the latest intelligent control systems, connectivity and advanced monitoring tools, it is possible to optimise the operation of compressed air systems while set pressure and flow are being met. Sensor-based compressor control systems, for instance, can significantly increase the efficiency of the whole air compressor system by actively managing the integrated machines at their most optimum points possible – thereby reducing energy consumption and optimising maintenance needs. Remote monitoring systems also allow end users to monitor the performance of their air compressor from a computer, smartphone, or tablet. Smart
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