Air compressors play an essential role in many industrial and manufacturing operations, but producing compressed air also generates a considerable amount of heat. In many facilities, that heat is simply released into the surrounding atmosphere and lost.
With an air compressor heat recovery system, businesses can capture this energy and reuse it elsewhere on site. This can reduce reliance on conventional heating systems, lower overall energy costs and improve the environmental performance of an operation.
Why Do Air Compressors Generate Heat?
Compressing air requires electrical energy. During the compression process, much of that energy is converted into heat, which must be removed to keep the compressor operating at a safe temperature.
Without heat recovery, warm cooling air may be discharged outside, while heat from the compressor’s oil circuit is removed through a cooling system. Although this heat is necessary to manage, it does not always have to be wasted.
A properly designed heat recovery system can redirect it towards a useful application within the facility.
How Can Recovered Heat Be Used?
The most suitable use will depend on the compressor, operating hours, site layout and the facility’s demand for heat.
Common applications include:
Heating Workshops and Warehouses
Warm air from an air-cooled compressor can be ducted into nearby production areas, workshops, warehouses or plant rooms. During colder months, this can reduce the amount of energy required from the building’s existing heating system.
Controls and ducting can also be designed to divert the warm air outside when heating is not required.
Producing Hot Water
Heat can be recovered from the compressor’s oil circuit using a heat exchanger. The recovered energy can then be used to heat or preheat water for applications such as:
- Washrooms and staff facilities
- Cleaning processes
- Space-heating systems
- Process water
- Boiler feed-water preheating
By increasing the temperature of the incoming water before it reaches a boiler or separate heating system, the amount of additional energy required can be reduced.
What Are the Benefits of Air Compressor Heat Recovery?
Reduced Energy Costs
Your business has already paid for the electricity used to operate the compressor. Recovering some of the resulting heat allows that energy to provide an additional benefit elsewhere on site.
This can reduce demand on boilers, electric heaters and other conventional heating equipment.
Lower Environmental Impact
Reusing heat that would otherwise be lost can reduce a facility’s overall energy consumption and associated carbon emissions. This can support wider sustainability objectives without affecting the compressed-air supply.
Better Use of Existing Equipment
Heat recovery can often be considered for both new compressor installations and suitable existing systems. This means businesses may be able to improve site efficiency without replacing their entire compressed-air system.
Improved Workplace Comfort
Where recovered warm air is used for space heating, it can help maintain a more comfortable temperature in workshops, warehouses and other working areas during colder periods.
Is Heat Recovery Suitable for Every Site?
The potential benefit depends on several factors, including:
- Compressor size and type
- Daily and annual operating hours
- Compressor loading
- Distance between the compressor and the intended use
- Existing heating requirements
- Seasonal demand
- Current fuel and electricity costs
For example, a compressor that operates consistently throughout the working day may provide a more reliable source of recoverable heat than one used only occasionally.
The location of the plant room is also important. If the area requiring heat is close to the compressor, installation may be more straightforward and heat losses can be minimised.
Start With a System Review
Before installing heat recovery equipment, the complete compressed-air system and the site’s heating requirements should be assessed. This helps determine how much useful heat may be available, where it could be reused and which recovery method is most appropriate.
PCM Air Power can review your existing compressed-air installation and develop a heat recovery solution tailored to your equipment, operating patterns and facility requirements. Solutions can be incorporated into a new compressor project or considered as a retrofit for a suitable existing system.
Turn Wasted Heat Into Useful Energy
If your air compressor is producing heat that is currently being discharged, your business may be missing an opportunity to reduce energy costs.
Contact PCM Air Power today to arrange a system review and discover whether air compressor heat recovery could benefit your facility.
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