Direct electricity consumption for compressed air accounts for 15%–30% of an enterprise's total energy use. Its energy conversion efficiency is low-only 10%–15%-with significant energy losses occurring during production, transmission, and utilization; these losses primarily manifest as thermal energy, mechanical losses, and pressure potential energy. Compressed air accounts for 20% of electricity consumption in industries such as iron and steel, and as much as 40% in sectors like textiles and chemical fibers.
Five fundamental activities for energy conservation in compressed air systems include: minimizing compressed air demand while still meeting production requirements; selecting safer, more energy-efficient supply pressures through analysis and testing; optimizing the structure and configuration of air compressor stations to maximize supply-side efficiency; scientifically planning the system to minimize energy losses during transmission; and implementing refined, visual energy management to effectively combine advanced technologies with scientific management practices.
Key technical approaches to improving energy savings include monitoring the entire system-equipment and piping networks alike-using sensors (for flow, pressure, and dew point) and communication networks, and developing expert control systems for compressor clusters that focus on the comprehensive management of end-use equipment. Additionally, smart electricity and gas meters are used to collect data on usage patterns; this data feeds into databases and IoT networks, enabling analysis that adaptively matches air compressors and post-treatment equipment to optimal operating conditions and dynamically adjusts system efficiency in real-time. Specific technologies employed include permanent magnet variable frequency drives and two-stage compression.
Furthermore, as a power source, compressed air holds significant application potential and research value in specialized fields such as pneumatic launching (e.g., for drone takeoffs).
