Compressed air system optimisation Sounds cumbersome, but yields 50 t CO² savings annually
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Defined as a key topic for EVVA GRI 302: Energy; 305: Emissions UN Sustainable Development Goals (SDGs), No 7: Affordable and clean energy; No. 12 Sustainable consumption and production

Behind the name "compressed air system optimisation" lies a small technical revolution at EVVA. Recently, three main compressors were still operating in three independent networks at the headquarters. They supply the compressed air for many manufacturing processes, e.g. for transporting parts within the machine. Disadvantage: If a compressor failed, there was a problem delivering compressed air to the respective area. In addition, the compressors were unevenly loaded because they each had a different number of consumers.

The solution: A superordinated ring main system was used. The ring system now digitally controls and connects 4 compressors. They are now evenly loaded. This "Industry 4.0" project provides intelligent air pressure control and reduces maintenance costs.

Very high energy savings

After production machinery, compressed air generation is EVVA's second largest electricity consumer. Instead of 270, the new compressed air network now only needs around 200 kilowatts of power. Thus annual electricity consumption is reduced. 80,000 kWh, that's almost 50 tonnes of CO² savings per year, or as much as 16 private households consume per year.

Our targets

Fulfilment date: 2022

How: The heat recovery system currently consists of a flap in the exhaust air duct. In winter, the machine heat is conducted into the hall, thus saving heating gas; in summer, it is dissipated, thus saving energy for cooling and air-conditioning systems. In order to make the waste heat usable in other parts of the building, a heat exchanger is installed on a large compressor, which directs the waste heat into the heating return and thus further reduces the demand for natural gas.

Positive effects: The potential savings in the 2019 energy audit are estimated at 168,000 kWh per year, which corresponds to the consumption of approx. 35 private households.

Fulfilment date: 2021

How: Leaks occur mainly in the supply lines to the machines (directly next to the valves) and cause unnecessary energy consumption. Further leaks are to be identified by the end of 2021.

Positive effects: The elimination will reduce energy consumption by an estimated 80,000 kWh per year. The actual savings are subsequently assessed by means of an external compressed air audit.

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