Atlas Copco ES master control system – a practical case study

We measured four 90 kW load/unload compressors at an engineering company.

We found that the compressors operate at around 80% utilisation across three shifts, producing approximately 30 million Nm3 of air per year.

The current cost of producing 1 Nm3 of air is CZK 0.4, meaning the company spends approximately CZK 12 million a year on electricity for air production.

As the compressors are controlled solely by a preset pressure cascade, around 20% of this energy is consumed during unloaded running. This wasted energy can be reduced by installing a master control system that manages compressor operation using its own control logic and pressure sensors distributed throughout the production facility.

Unloaded running cannot be eliminated entirely, but it is expected to be reduced by at least half, which would save CZK 1.2 million per year.

Another financial benefit is a lower average system pressure achieved by narrowing the control band. The estimated pressure reduction is around 0.5 bar, cutting energy costs by a further 3.5%, or CZK 300,000 per year. The master control system costs approximately CZK 500,000. Implementing the proposed solution would also reduce the cost of producing 1 Nm3 to approximately CZK 0.35/Nm3.

Interested in the economics of compressed air? Have your own operation analysed – Compressed air production cost analysis. Or attend our seminar.