ICO-Air is ICOPOWER 's patented technology that significantly lowers the energy costs of production facilities that use compressed air. An intervention that can ensure a reduction in consumption between 10% and 40%, guaranteeing greater energy efficiency.
Almost all of today's industries and SMEs employ significant amounts of compressed air for automations and their industrial processes. The production of air must be able to satisfy the many utilities that, with different times, durations and behaviors, enable the production cycle. This results in a variable draw of air from moment to moment.
The variability of operating conditions is the real challenge for compressed air production in an efficient mode. Energy consumption and increased efficiency is an increasingly crucial goal, both as a business strategy for increasing profits and as an environmental protection policy.
The only value the compressor reads is the pressure inside the reference tank. This is the one and only target parameter, called thepressure set point. The pressure set point is a constant value, set during system sizing, despite the variability of compressed air absorptions.
The inverter compressor reaches maximum efficiency when it modulates its output, that is, near the operating point (pressure set point). In case of significant and rapid air demands, the compressor leaves the modulation zone and is forced to work at full capacity, losing efficiency. Often in companies, the variability of compressed air consumption in production islands is such that it causes this phenomenon.
The presence of leaks along the distribution system and the need for appropriate pressure even at the machinery at the end of the line often force the set point of the compressors to be oversized. This phenomenon moves the compressors away from the optimal working point (high-efficiency modulation zone).
Oversizing the set point causes an increase in the average pressure in the dstribution ducts and a consequent higher air leakage.
The ICO-Air system reduces inefficiencies arising from the compressed air distribution system. the activity is mainly based on two elements:
The ICO-Air system enables the reduction of operation/work of compressed air production systems through the installation of components (flow and pressure sensors and motorized valves) whose location can be identified before and after the storage tank, as best depicted in the summary diagram below.
Through current sensors connected to the power supply of the compressors, ICO-Air detects the electrical consumption required for compressed air production at any given moment. This information is constantly processed by ICO-Air's artificial intelligence.
A motorized valve and a sophisticated hot-wire sensor system are installed downstream of the tank for real-time detection of all pneumatic parameters. In this way, ICO-Air processes the continuous changes in compressed air demand from the company and compares them with the electrical activity of the compressors.
The continuous comparison of compressed air demand and the electrical behavior of compressors allows ICO-Air to modulate the pressure sensed by the compressor. Through a motorized valve, the system allows the compressor to work for a longer time in its own high-efficiency zone.
To ensure air supply to production facilities in all situations, the ICO-Air system provides both manual bypasses on the motorized valves and an always-connected bypass pipeline.
The artificial intelligence of ICO-Air produces improved energy efficiency of the compressed air station and, at the same time, an opportune reduction of the average pressure in the reservoir, in full compliance with the parameters required for the operation of the company's plants.
The Icopower offer includes a contractual guarantee of the specified performance.
In case of failure to achieve the guaranteed result, the Client is reimbursed.
The result is guaranteed by a proprietary patent, testing proving the reduction in consumption, constant monitoring during normal plant use, and timely verification of the reduction in KWh reported on the bill, month by month.
The bypass system makes it possible to maintain the supply of compressed air to company facilities at all times.
ICO-Air apparatuses are internally equipped with measurement instrumentation that allows data collection and processing to occur with extreme precision.
The ICO-Air activity enables the reduction of compressor working hours while maintaining the plant's productivity.
ICO-Air enables the reduction of compressor working hours devoted solely to the physiological feeding of system losses.
The system does not interfere in any way with the compressors but acts only at the electromechanical level on the air storage station, without compromising and/or tampering with equipment that may be the subject of other third-party maintenance contracts
Less stress on the compressed air station, results in increased longevity and performance of the Customer's compressors.
Management of the performance data collected, allows the construction of KPIs (Key Performance Indicators) and other indicators, all from the perspective of developing the company's best production "habits."
All control parameters are stored on encrypted and redundant servers in the cloud.
In perfect adherence to the 4.0 architecture, Icopower solutions communicate bidirectionally, both for sharing performance data and for receiving controls, commands and new programming.
The Icopower monitoring architecture rests on the cloud and therefore allows access from any device (pc, tablet, smartphone, etc...) with an internet connection and login credentials.
Icopower's energy efficiency offerings include a contractual performance guarantee. This means that the Client has the protection that their investment in energy efficiency will produce the expected results.
All models in the ICO-Air range are equipped with measurement instrumentation that continuously measures the energy efficiency parameters obtained.
Icopower is contractually committed to performance, protecting the Client with a covenant of repayment.
Maximum transparency, maximum peace of mind.
The ICO-Air technology is covered by an international patent attesting to the effectiveness that can be generated at companies' compressed air stations.
ICOPOWER systems meet the parameters defined by the Ministry of Economic Development(MISE) and the Gestore dei Servizi Energetici(GSE) to take advantage of the tax benefits provided by the National Industry 4.0 Plan, which, when added to the actual energy savings, allow the payback period to be considerably reduced, in favor of greater competitiveness for Customers.
For capital goods 4.0-such as ICO Air-the customer benefits from a tax credit equal to 20 percent of the cost for the portion of investments up to 2.5 million euros.
ICO-Air has been certified as a 4.0 capital asset and also enjoys Bureau Veritas certification for obtaining the tax credit.
The cost of leasing can be reduced to zero for companies can take advantage of the so-called "New Sabatini": a facility made available by the MISE for micro, small and medium-sized enterprises.
This facility allows for a subsidy on the requested loan of 3.575 percent per year for investments in Industry 4.0 technologies.
Energy Efficiency Certificates are tradable securities that certify the achievement of savings in energy end-use resulting from the implementation of specific energy efficiency measures.
ICO-Air has already been awarded Energy Efficiency Certificates, on energy efficiency interventions at customers who have applied for them.
MADE is a Competence Center for Industry 4.0 created to carry out Orientation, Training and Finalization activities for technology transfer projects with companies on Industry 4.0 issues.
A technical interlocutor that companies can turn to for support during the digital transition phase to a smart factory. The first contact with companies that are not aware of the Competence Center's offer is that of their orientation to increase their awareness of Industry 4.0 issues, with the aim of developing training paths dedicated to technicians, but also to the strategic profiles of companies and carry out technology transfer projects.
Icopower exhibits its technologies in operation at the Made headquarters on the campus of the Milan Polytechnic University. Here you can view our energy efficiency solutions and, at the same time, understand how to take advantage of our compliance with the National Industry 4.0 Plan (now"Transition 4.0").
Every energy efficiency bid that Icopower issues contains specific information about the environmental benefits that can be achieved by installing ICO-Air.
Our customers benefit from valuable information that they can use in
green marketing activities , in sustainability reporting and in improving
their carbon footprint.
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