Aire Comprimido - Conceptos

8/6/2019 Aire Comprimido - Conceptos

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Compressed Air

Technology Concept


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US DOE Industries of the Future Workshop Series

Compressed Air Background

Important industrial energy sourceInherently inefficient

Consumes up to 20% of industrial electrical

usage

Great energy & cost

savings potential!

$$$


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Lifetime Operation vs. First Cost

Equipment

12%

Maintenance

12%

Electricity

76%

Typical LifetimeCompressed Air

Costs Over 10 years

Assumptions include a 75-hp compressor

operated two shifts, 5 days a week at an

aggregate electric rate o $0.05/kWh over10 years of equipment life.

Source: US Dept of Energy, Office of Industrial Technologies:

Compressed Air Tip sheet #1.

http://www.oit.doe.gov/bestpractices/pdfs/compressed_air1.pdf
http://www.oit.doe.gov/bestpractices/pdfs/compressed_air1.pdfhttp://www.oit.doe.gov/bestpractices/pdfs/compressed_air1.pdfhttp://www.oit.doe.gov/bestpractices/pdfs/compressed_air1.pdf


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Compressed Air Energy

Inefficient power source even if well maintained

Eight compressorhorsepower

One horsepower ofcompressed air

}yields . . .


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Compresse

air energy

15%

Heat of

compressio

85%

Compressed Air Energy

Leaks5%

End users9%

Pressure drop

2%

Heat ofcompression

84%

Ratio: 8:1


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Compressed Air System

Supply Compressor

System Controls

Air Dryer

Aftercoolers

Air Filters

Primary Storage

Flow controls

Distribution Air piping

Filters, lubricators,regulators

End Uses

Pneumatic tools

Mechanical drive

Blowers Vacuum generators

Etc . . .


7/53US DOE Industries of the Future Workshop Series

Supply compressor types

Compressors

Positive Displacement Dynamic

Reciprocating

Rotary

Centrifugal Axial

Single Acting

Helical Screw Scroll

Double Acting

Liquid Ring Sliding Valve



Supply compressors

Reciprocating

Very efficient

Requires frequentmaintenance

Can be equipped for veryefficient part loading

Can be multistaged



Supply compressors

Rotary Screw Easy to install

Enables modulationcontrol

Easy to maintain Can be single or doublestaged

Source: Gardner Denver



Supply control types

0%10%20%30%40%50%60%70%80%90%

100%

110%

0% 20% 40% 60% 80% 100%

% Air Flow Capacit

Average

Power(%FullLoad)

Variable Speed Load/Unload 3 gal/cfm storag

Turn Valve Straight ModulationModulation w/blowdown

On/Off (not pictured)

(Outlet modulation) (Inlet)

(Inlet)



Variable Speed Drive Compressors

Allows precise matching of supply and demandExtremely efficient at low load

Less efficient that standard compressors at full load

Retrofitting standard compressors is problematic

Not ideal for every application

Best for precise constant pressure applications


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Supply dryers

Regenerative desiccant

Water vapor is adsorbedby desiccant fill

Low air dew points (-40Fto -100F

Heated or unheated

Requires 3-15% purge air

No condensategenerated

Source: Palatek



Efficient compressed air systems

Proper performance yields Low operating costs

Minimal downtime

Clean, dry, dependable air

Effective process control



Why make a change?

Great energy & cost savings potential!

$$$

Save energy (25% or more)

Reduce downtimeProduce clean, dry air

Eliminate maintenance crises


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Technology - Common SystemImprovements



Benchmarking

Determine average power draw (kW)

Determine total energy costs

Determine marginal generation efficiency (kW/scfm)

Calculate energy savings potential for system improvements

Worksheet Estimate Your Compressed Air Cost


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Common problem areas

Air Leaks

No heat recovery

High pressure drop

Insufficient air storage

Ineffective control strategy

Multiple compressor operation not optimized

Base load vs. trim compressor

Inappropriate end uses

Poor record keeping Electric usage

Air production


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Air leaks

When was your last leak survey?

Poorly maintained systems

Up to 40% leak rate Pressure problems

We need to install another compressor.

Leak surveys should be conducted quarterly!


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}8 compressor horsepoweryields 1 horsepower ofcompressed air . . .Heat recovery

Where does the other7 horsepower

go????

HEAT.HEAT.


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MMBtu

$5

Btu101

MMBtu1

year

hr4,000

hr

Btu300,000

6

80% of compressor input power may be recoverable

Possible uses Space heating

Hot water heating

Drying/curing room heating

Heat source for desiccant dryer100 hp @ full load 300,000 Btu/hr

Heat recovery

$6,000=


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Heat recovery

Compressor

Winter Operation

Hot air to

Plant


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Heat recovery

Compressor

Summer Operation

Hot air Exhausted


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Pressure drop compressor room

Compressor

Filter Filter

Compressor

StorageTank

Air Dryer

StorageTank

To PlantCompressor

Tee junctions

Unnecessary piping High P dryer

Short radius elbowsHigh P filters


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Pressure drop (continued)

Distribution

Worksheet Calculating the Cost of High Pressure

Drop

GOAL: 0 4 psigpressure drop incompressor room


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Air storage

Rule of Thumb 4 gallons of storage percompressor cfm

Remote storage for high periodic demands

Wet vs. dry storage

Piping rule

In at the bottom Out at the top!


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Air Storage Compressor Loading

0

20

40

60

80

100

120

0 10 20 30 40 50 60 70 80

Time (sec)

Power(k

W)

Unloaded

Blow down

Loaded

Unloaded

100 hp compressor with load/unload controls


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0

20

40

60

80

100

120

0 25 50 75 100

125

150

175

200

225

250

275

300

325

Time (sec)

Power

(kW)

Inadequate Storage (1 gal/cfm)

Average Power = 82.9 kW

Compressor is fully loaded (delivering air) for 130 seconds


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0

20

40

60

80

100

120

0 25 50 75 100

125

150

175

200

225

250

275

300

325

Time (sec)

Power(kW)

Improved Storage (3 gal/cfm)

Compressor is fully loaded (delivering air) for 130 seconds

Average Power = 63.0 kW


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Air Storage

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

0% 20% 40% 60% 80% 100%

% Air Flow Capacity

AveragePower(%FullLoad)

Load/Unload 1 gal/cfm storage Load/Unload 3 gal/cfm storage

Load/Unload 5 gal/cfm storage Load/Unload 10 gal/cfm storage

Energy

Savings

Generalized energy savings for increased storage in load/unload compressors


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Compressor controls

Control strategies impact compressor energyconsumption

0%10%20%30%40%50%60%

70%80%90%

100%110%

0% 20% 40% 60% 80% 100%

% Air Flow Capacit

AveragePower(%

FullLoad)

Variable Speed Load/Unload 3 gal/cfm storageTurn Valve Straight ModulationModulation w/blowdown


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Compressor controls

Using the Most Efficient Control Strategy worksheet


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Inappropriate End Uses

Anything that can be done More effectively by another method

More efficiently by another method


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Inappropriate End Uses - Examples

Open blowing - Cooling, drying, clean-upSparging - Aerating, agitating, oxygenating,percolating

Aspirating - Inducing flow in another gas (e.g., fluegases)

Atomizing - Dispersing or delivering a liquid to aprocess as an aerosol

Dilute phase transport - Transporting solids such aspowders

Dense phase transport - Transporting solids inbatches

continued


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Inappropriate End Uses - Examples

Vacuum generation - used with a venturi to generatenegative pressure mass flow

Personnel cooling

Open blowguns or lances

Diaphragm pumpsCabinet cooling


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Application of new technologies/concepts

Variable speed compressors

Zero loss drains

Air amplifying nozzles

Solenoid shut off valves

Demand Controller


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Zero Loss Drains

Timer drains either:Waste air

Fail to remove all liquid

Zero loss drainsremove liquid with no

air loss


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Blow off manifolds

Air Amplifiers

Amplifiers entrain still air to increase

air flow from blowing components

Advantages

Increase blowing force

Significantly reduced compressed airusage

Reduced noise

Fully adjustable

Applications

Source: ARTX

Hand blow guns

Air curtains/knives


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Electric Solenoid Valves

Reduce leaks in piping toequipment that is shut off

Timer control

Machine panel control

Manual control


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Demand Controllers

Isolate supply side fromdemand side of system

Appropriate only with

adequate storage

Help reduce air usage byminimizing pressure delivered

to end users

Source: Zeks Compressed Air Solutions


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How do I optimize the performance of my compressed air system?

Implementation requires participation

ProductionMaintenance

Management

Improving system performance

Assessing the entire system

Identifying opportunities

Quantifying benefits and costs Implementing most feasible projects

Systems approach (supply and demand)


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IAC implementation trends and analysis

DescriptionTimes

Recommended

Implementation

Rate

Average

Simple

Payback

(yrs)

Eliminate leaks in compressed air lines/valves 4,529 74% 0.3

Reduce the pressure of compressed air to the

minimum required2,193 42% 0.3

Eliminate or reduce compressed air used for cooling,

agitating liquids, moving product, or drying568 44% 0.7

Eliminate permanently the use of compressed air 127 41% 1.2

Remove or close off unneeded compressed air lines 53 42% 1.2

Cool compressor air intake with heat exchanger 22 36% 1.5

Substitute compressed air cooling with water or air

cooling20 35% 0.9

Do not use compressed air for personal cooling 18 50% 0.7


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How to start

Steps in evaluating your system

Monitoring needs

Best Practices

Pitfalls

Treat compressed air like a fourth utility.


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Monitoring

Air Pressure Problems

Compressor Loading

Power consumption

Air Consumption

Track using MS Excel or similar program


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Pitfalls

Running at too high a pressure

Considering compressed air as a free utility

Higher pressure = more air

Adding compressor horsepower to combat pressure

problems Always have a compressed air audit completed before

adding additional compressors.

Inadequate storage/piping


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Benchmarking revisited

Benchmarking should be part of a larger plan

Commit toContinuousImprovement

AssessPerformance

SetGoals

CreateAction Plan

ImplementAction Plan

Evaluate

Progress

Re-AssessGoals


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In house assessment Tools available from US DOE Air Challenge Program

Assessing Resources

Equipment manufacturers

Private energy service companies

Energy Resources Center @ UIC

US DOE Industrial Assessment Centers

GO

TO

Comp

ressedAirR

e

sour c

eList


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Assessment Resources

Energy Resources Center @ UIC www.erc.uic.edu - can provide

expertise in industrial compressed air systems, also will perform energyassessments for industrial clients.

Industrial Assessment Centers http://www.oit.doe.gov/iac/ - will provideenergy assessments (including compressed air systems) free of chargeto qualified industrial clients.

US DOE Compressed Air Challenge Programhttp://www.compressedairchallenge.org/ - provides a wide range oftechnical assistance materials, tools, and services to the industrialmarket.

National Association of Energy Service Companieshttp://www.naesco.org/ - trade organization of companies that will

perform energy audits and finance improvements. Rutgers IAC Self Assessment Guide

http://iac.rutgers.edu/manuals/selfassessment.pdf- guide to assessingindustrial plants for energy efficiency.
http://www.erc.uic.edu/http://www.oit.doe.gov/iac/http://www.compressedairchallenge.org/http://www.naesco.org/http://iac.rutgers.edu/manuals/selfassessment.pdfhttp://iac.rutgers.edu/manuals/selfassessment.pdfhttp://www.naesco.org/http://www.compressedairchallenge.org/http://www.oit.doe.gov/iac/http://www.erc.uic.edu/


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Hyperlinked Slides


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Assessment Resources

Energy Resources Center @ UIC www.erc.uic.edu - can provide expertise in

industrial steam systems, also will perform energy assessments for industrialclients.

Industrial Assessment Centers http://www.oit.doe.gov/iac/ - will provide energyassessments (including steam systems) free of charge to qualified industrialclients.

US DOE Steam Challenge Program

http://www.oit.doe.gov/bestpractices/steam/ - provides a wide range oftechnical assistance materials, tools, and services to the industrial market.

National Association of Energy Service Companies http://www.naesco.org/ -trade organization of companies that will perform energy audits and financeimprovements.

Steam System Survey Guidehttp://www.oit.doe.gov/bestpractices/steam/pdfs/steam_survey_guide.pdf-guide to assessing industrial steam systems.

Rutgers IAC Self Assessment Guidehttp://iac.rutgers.edu/manuals/selfassessment.pdf- guide to assessingindustrial plants for energy efficiency.

BAC

KTO

Pre

sentat io

n
http://www.erc.uic.edu/http://www.oit.doe.gov/iac/http://www.oit.doe.gov/bestpractices/steam/http://www.naesco.org/http://www.oit.doe.gov/bestpractices/steam/pdfs/steam_survey_guide.pdfhttp://iac.rutgers.edu/manuals/selfassessment.pdfhttp://iac.rutgers.edu/manuals/selfassessment.pdfhttp://www.oit.doe.gov/bestpractices/steam/pdfs/steam_survey_guide.pdfhttp://www.naesco.org/http://www.oit.doe.gov/bestpractices/steam/http://www.oit.doe.gov/iac/http://www.erc.uic.edu/

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