Stoke Depot Opening Times: 07.30am – 5.00pm Mon to Fri | Shrewsbury Depot Opening Times: 08.00am – 5.00pm Mon to Fri
Stoke Depot Opening Times: 07.30am – 5.00pm Mon to Fri | Shrewsbury Depot Opening Times: 08.00am – 5.00pm Mon to Fri
J Ll Leach supplies and installs advanced flow monitoring and energy recovery systems for air compressors from our Stoke, Birmingham and Shrewsbury branches.
Air compressors convert most of their electrical energy into heat. In fact, up to 94% of the electrical energy supplied to a compressor is converted into heat during compression. Without an effective energy recovery system, this valuable thermal energy is lost through cooling systems and vented into the atmosphere.
This waste is a significant, often hidden, operational cost, as energy can account for up to 80% of a compressor’s total life-cycle costs. Functionally, a compressor operates like an expensive electric heater that provides compressed air as a byproduct. Implementing heat recovery technology is one of the most effective energy-saving strategies available.
J Ll Leach has been working with air compressors since 1936. We work from three depots in Stoke-on-Trent, Birmingham and Shrewsbury.
When air gets compressed, it heats up. This is known as the heat of compression. Compressors use fans or water cooling to remove this excess heat to maintain safe operating temperatures. Heat recovery systems capture some of this thermal energy before it’s lost.
The recovered heat energy can be used for:
Most systems recover heat at 60-70°C, which is suitable for many heating applications. However, more advanced water-cooled systems can generate hot water up to 95°C.
The type of compressor you have dictates the potential for heat recovery.
Most compressors can be fitted (retrofitted) with heat recovery systems. Air-cooled machines are simpler to modify than water-cooled ones.
We check several things during site surveys:
Some older compressors may need modifications to cooling systems or electrical controls.
Heat recovery systems typically pay for themselves within 1 to 3 years through reduced heating and energy costs. Some high-utilisation systems see a payback in under 12 months.
A 22kW compressor running 8 hours daily might recover 15kW of heat. At current energy prices, this could generate huge savings of around £2,500 annually on heating bills.
Actual cost savings depend on:
Investing in an energy recovery system is also highly tax-efficient for UK businesses. Qualifying equipment is eligible for 100% first-year capital allowances through the government’s Full Expensing (FE) scheme (for companies paying Corporation Tax) or the Annual Investment Allowance (AIA). This allows you to deduct the full cost from your pre-tax profits in the year of purchase, significantly reducing the net cost of the investment.
For new compressor installations, we can include heat recovery in the initial design. This reduces overall costs and eliminates the need for later modifications.
Retrofitting existing systems involves:
Most installations are completed during planned maintenance shutdowns or weekends.
Heat recovery systems need regular checks:
We include these checks in our regular maintenance visits. Most components last as long as the compressor itself.
Building regulations may apply to external ducting or flues. We advise on requirements during the survey stage.
In the Midlands, many older industrial buildings have asbestos insulation. We work with certified contractors when modifications affect existing services.
Planning permission isn’t usually needed for heat recovery systems, but we check local authority requirements for each project.
We’ve been installing compressed air systems across the region for over 80 years. Our engineers know local industrial requirements and building standards.
As Premier Atlas Copco Premier Distributors for the UK, we stock genuine components and have factory training on their advanced heat recovery systems. We are experts in specifying and integrating dedicated Atlas Copco ER systems and using the Elektronikon® controller to manage and monitor energy recovery, ensuring optimal performance without compromising compressor safety. We also service other compressor makes.
Our installations include:
We can assess your compressed air system for heat recovery opportunities. Our survey covers compressor specifications, running hours, available space, and existing heating requirements.
We provide written quotations showing estimated costs, potential cost savings, payback periods, and a full heat recovery calculator analysis to model your potential ROI. Get in touch to arrange your no-obligation site survey.
Typically 70-80% of electrical input can be recovered as useful heat. A 30kW compressor might provide 20-25kW of heating. With modern oil-free compressors, this figure can be as high as 94%.
No. The compressor operates normally. The air compressor heat recovery system uses thermal energy that would otherwise be wasted. Modern controllers, like the Atlas Copco Elektronikon, manage the process to ensure the compressor’s cooling needs are always prioritised.
Most rotary screw compressors from the last 15 to 20 years can be equipped with heat recovery. Older machines may require modifications to their cooling systems.
Heat exchangers need periodic cleaning. Water systems require annual checks for corrosion. We include these in our service schedules.
Simple air systems might be completed in a day. Water systems with extensive pipework can take several days depending on building layout.
Heat recovery systems don’t usually require planning permission. External flues or ducting may need building regulation approval.
The two main types are air systems and water systems. Air systems use hot air for direct space heating. Water systems use heat exchangers to generate hot water, which is more versatile and can be used for process applications like pre-heating boiler feedwater or for washing.
This is a common challenge. For hot air systems, thermostatically controlled dampers automatically vent the hot air outside. For water systems, the heat can be decoupled using a thermal storage tank (hot water accumulator), allowing you to store the energy until it’s needed, or a bypass circuit can simply route the water to a standard cooler.