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. In the previous reporting period 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 only needs around 200 kilowatts of power. This reduces the annual electricity consumption by  80,000 kWh.

Our targets

Fulfilment date: 2022 (Several compressors are already integrated. This 2022 target will only be completed until the final figures are available in the course of 2023. They document the actual savings.)

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, heat exchangers are installed on the compressors, which direct the waste heat into the heating return and thus further reduce the demand for natural gas.

Positive effects: In the energy audit the potential electricity savings are estimated at 168,000 kWh per year, which corresponds to the consumption of around 50 private households.

Fulfilment date: Primary until 2021 - now target savings doubled and the period extended to 2024

How: Leaks occur mainly in the supply lines to the machines (directly next to the valves) and cause unnecessary energy consumption. By the end of 2021, leaks should be discovered and due to their elimination around 80,000 kWh per year can be saved. This target has now been expanded. In the new period until 2024, leaks in operating resources are also to be gradually eliminated. Therefore EVVA is doubling the original savings potential.

Positive effects: Instead of 80,000 kWh as in the primary target, this should reduce energy consumption by 160,000 kWh by 2024. The actual savings will be made susequently via an external compressed air check. With the previous exchange of pipes, it was already possible to reach 20% of the target.

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