Do you know that you can save up to 40% of electricity with high-quality air management?
Compressed air is considered the fourth energy and is used by almost every industrial operation, from small workshops to nuclear power plants. However, the production of compressed air is expensive and therefore it is important that each operation is set up in such a way as to optimize the overall characteristics of the production system.
Balance of operating costs
A key issue in automated manufacturing is the balance of operating costs. Each automated operation uses a different form of carrier energy. If this energy is compressed air, then it is important to analyze the amount of compressed air consumption and how to deal with it. This is precisely the main reason why a regular and professional energy audit must take place in the automated operation.
Compressed air is one of the most frequently used energy sources in industry and commerce. The input costs for the production of compressed air compared to other energies make the operation of pneumatic mechanisms more expensive. However, the important thing is that there is a way to achieve savings. First of all, it is essential that the operation meets the basic conditions.
Conditions for the compressed air distribution project
- OPTIMIZATION the inner diameter of the pipes (clearance) must be optimized, taking into account the application needs of the flow
- TIGHTNESS The joints must be absolutely tight
- MAINTENANCE air pressure in the circuit must be maintained at the level necessary for operation
- LOCATION of fittings in the distribution system should be located so that easy maintenance is possible (replacement, repairs, checking for leaks)
It is important to check the tightness of the joints. First of all, the check takes place during the first pressurization of the system, before the mechanisms are started and without air consumption. After this check, the detected leaks will be sealed. If the tightness of the distributions is satisfactory, the test is repeated after eg again after one month. However, such a process is time-consuming and requires a certain amount of experience.
Cost reduction thanks to professional auditing
Many times these are trivial errors that arise from unprofessional intervention. These errors can be noted when performing a consumption audit. Compressed air is often wasted due to the use of too high a pressure in the entire circuit for the one drive that needs that pressure. This situation can be solved by using a suitable multiplier and by adjusting the standard operating pressure to the required level just for the control valve of the specific drive. By finding and solving problem areas in the circuits, it is possible to ensure effective rationalization of costs and thereby reduce the long-term operating costs of automated lines.
With high-quality air management, you will not only save electricity and operating costs, but at the same time you will also reduce emissions in the air of our planet.
We will provide a professional audit in your operation as well. Do not hesitate to contact us.
Source: Ing. TULEJA.P, PhD., Ing. ŠIDLOVSKÁ Ľ., Energy saving strategy in automated operations using compressed air, Transfer of innovations 30/2014