Basics of Compressed Air Applications and Costs
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Introduction and Applications for basic of compressed air
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Basics of Compressed Air Applications and Costs
- 1. 01 Basics of Compressed Air A - Introduction & Applications Product Line Training Product Line - Industrial Filtration Technology Status: July 2010
- 2. 2 Content • History • Advantage • Costs • Applications
- 3. 3 History The first known compressor… Technical Data: Compressor: Membrane type Pressure Rate: ≈ 0,02 – 0,08 bar Volume Flow: ≈ 6 m³/h Special features: Excellent reliability Min. maintenance required …with limited application spectrum.
- 4. 4 History Bellows = First mechanical compressor Opening of temple doors with help of expansion of hot air + displacement of water volume + creation of work / force Pneumatic catapult – use of accumulated energy in a compressed air cylinder 3000 B.C 200 B.C 100 A.C. First antique compressed air applications
- 5. 5 History Compressor Stations 1800 1900 2000 Underground Pneumatic Delivery Blasting Pneumatic Tools Paint Spraying Semiconductor Industry Breathing Air Laser Industry Food & Beverage Compressed air applications of the last 200 years
- 6. 6 Content • History • Advantage • Costs • Applications
- 7. 7 Advantages Easy transportation of energy • Everywhere available • No return-line required – used air can be released to ambient • Can be transported over great distance in pipe systems Easy storage • Can be stored in pressure vessels • Energy is available when compressor is not running • Transportable in areas where no compressed air system is available (e.g. under water)
- 8. 8 Lightweight • Pneumatic componentes are leightweight compared to hydraulic + electrical components Reliable in operation • Long service life of pneumatic components • Can operate in areas with explosion risk, in rough ambient, at high or low ambient temperatures Simple • Simple structure and function of pneumatic componentes • Easy installation and service Advantages
- 9. 9 Safety operation • Low potential danger compared to electrical components • Low potential risk of component damage when compressed air system is overloaded by high consumption. Pressure drops – work energy is not available – but no damage on system components. Flexible working fluid • Extremely fast movement possible • Infinitely variable control of velocity, torque and force possible • Compressibility of gaseous medium ensures smooth damping and delay action processes Advantages
- 10. 10 Content • History • Advantage • Costs • Applications
- 11. 11 Costs %100 el P mech P %100 P P comp el Electrical Energy Mechanical Energy Compressed Air Mechanical Energy %100 P P mech comp Cost per m³ compressed air (related to 7 bar pressure) • up to 0,01 € (1 Eurocent) at >100 kW installed power • up to 0,03 € (3 Eurocent) at systems with lower power + high quality Every transformation of energy costs money!
- 12. 12 Energy 73% Investment 19% Cooling water 1% Maintenance 7% Even in well-maintained networks, up to 50% of the generated compressed air is lost by leaks. From a different perspective: up to 50% potential savings are concealed in a system, and we are able to find them. The result: leakage rates and energy costs fall substantially Costs Up to 50% potential savings by leakage detection
- 13. 13 Leak Size Diameter Compressed air loss at 8bar operation pressure Lost Energy Costs (0,08 €/kWh) mm l/min kWh € / a (8000 h/a) 1 75 0,60 384,-€ 1,5 150 1,30 832,-€ 2 260 2,00 1.280,-€ 3 600 4,40 2.112,-€ 4 1100 8,80 5.632,-€ 5 1700 13,20 8.448,-€ Costs Costs of Compressed Air Leakages
- 14. 14 After-cooler, Separators+Filters, Dryers, Pressure Vessels, Valves, Pipelines, Fittings, … 7 bar = 6 bar + 1 bar + 1 bar ≈ + 10% energy cost Reduced flow Extended running time ≈ + 8K additional compression temperature Additional cooling energy needed Compressor Differential Pressure Δp = 1 bar7 bar Application 6 bar Costs Costs of Differential Pressure
- 15. 15 Additional enery costs caused by pressure drop (Operation Data: 6000 hr/year - 0,08 €/kWh - 1 bar = 10% more energy) 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 0 0,1 0,2 0,3 0,4 0,5 Pressure Drop [bar] Additionalannualenergycost[Euro] 110 kW 75 kW 45 kW 30 kW 22 kW 11 kW InstalledPower Costs Costs of Differential Pressure
- 16. 16 Content • History • Advantage • Costs • Applications
- 17. 17 Applications Compressed Air is an energy form offering an unrivalled range of applications and combining speed, power, presicion and safe handling. These characteristics makes compressed air irreplaceable in many cases. Working and energy air As an important field of application for compressed air, pneumatics has shown a two-digit growth rate for years. More and more new patents are being filed on compressed-air cylinders, air engines and compressed air valves. Characteristics of Compressed Air
- 18. 18 Compressed Air is the 2nd most used type of energy in industry… In Europe 10 % of all electricity (used by industry) is used to produce compressed air. Applications
- 19. 19 Regardless of the applications for filtration technology for which you are responsible: Donaldson is the partner! In decades of close coporation with our customers, we have gathered expert knowledge in nearly all fields of industrial production. Chemical industry Pharma industry Electronics industry Automotive industry Applications Laser Industry Breathing Air Painting Bio Gas Industry-specific filtration technology