Production Of Compressed Air Research Articles

METHOD AND MEANS OF INCREASING THE ENERGY EFFICIENCY OF COMPRESSED AIR PRODUCTION IN THE TECHNOLOGICAL PROCESS OF WOOD PROCESSING

Today, energy saving and energy efficiency are becoming more and more relevant and critical for modern enterprises, institutions and companies. Modern strategies in these areas are aimed at optimizing the use of energy resources and increasing the productivity of production processes. The high level of energy efficiency achieved is reflected in the competitiveness of products on world markets, thanks to the reduction of energy costs and the limitation of greenhouse gas emissions. Compressed air is an important resource for industry, often ranking fourth behind electricity, gas and water. The difference is that compressed air is produced on-site, giving consumers more control over its use and costs. However, the process of obtaining it requires significant energy costs. At enterprises in Europe and Australia, for example, compressor units that produce compressed air can use up to 10% of electricity, while in the United States this figure can reach 30%. Currently, the energy efficiency of the Ukrainian economy is twice as high as compared to world standards, which indicates inefficient use of heat, water and electricity. Therefore, it is important to understand that the implementation of measures for the energy efficiency of compressed air production is not only important from an ecological point of view, but also economically beneficial both for the country as a whole and for individual consumers. Increasing the level of energy efficiency of production processes, in particular wood processing, with the help of modern electrical engineering complexes, is a priority task for the industry. Thus, the analysis and development of energy-efficient solutions for the production of compressed air is a promising direction of development. This article provides an overview of well-known electrotechnical complexes that contribute to improving the energy efficiency of the technological process of wood processing.

Comparative analysis of compressed air production equipment

In this paper the main devices for the production of compressed air - compressors are considered. The text describes their classification according to the principle of operation and principles of operation, which shows one of the principle air circuits of the compressor system with an electric circuit control of the electric drive of the compressor on ships with the complex automation of the power plant. And also in our work provides a comparison of different models of bulk compressors to determine which compressors are needed for more comfortable and safe operation. Consequently, they noted the main advantages and disadvantages of the models under consideration. I would also like to note that compressors and compression equipment are used everywhere. It is used in all branches of industry, in construction work, car repair, food production, agriculture, as well as in any other activities of the modern man. Learn how compress or sand compression equipment work.

Decrease of the cost of drying compressed air by heat recovery at the compressor station

Compressed air is widely used as an energy carrier. The compressed air production systems are a part of the auxiliary systems of offsite facilities. It is worth noting that the production of com-pressed air is quite an energy-intensive process, so the potential for energy saving is quite large. There is increasing the efficiency of the compressed air production by developing technology solutions for air preparation in this work. The system of air drying by cooling and the source of cold are considered in this paper. The paper presents a comparison of cooling systems from steam compression and absorption refrigerating machines from the point of view of heat exchange, energy consumption for their own needs, providing cold with required parameters. The economic effect of the proposed circuit solution is given.

Energy saving potential analysis of a short cycling industrial air compressor in a marine equipment manufacturing plant in Türkiye

Compressed air systems are recognised as significant energy users and are characterised by their notably inefficient energy consumption. This ensures their significance and potential for decarbonisation through cleaner and more responsible energy consumption in manufacturing facilities, such as marine equipment manufacturing plants in the shipbuilding industry, in order to address the various economic and regulatory challenges related to energy use and climate change. In the relevant literature, there are numerous studies on various energy-saving measures for compressed air systems; however, none concentrates on the problem of short-cycling phenomena and associated energy-saving potential. In this study, using a novel and systematic energy audit methodology, a detailed energy audit of a rotary-type screw air compressor was conducted at a marine equipment manufacturing plant in Türkiye. The systematic energy audit methodology was based on the measurement of power consumption and the evaluation of various operation parameters to assess the existing performance of the compressor, including compressed air demand, compressed air production, cycle speed, air tank volume, specific capacity, and duty cycle. The audit results revealed that the air compressor was short cycling, resulting in excessive energy consumption. Comprehensive technical and economic assessments were conducted to determine the root cause of the compressor's short cycling and to identify energy-saving potentials. It was determined that the compressor was oversized relative to the plant's compressed air demand patterns, while the air tank was inadequately sized, causing the compressor to engage in short cycling. To replace the existing short-cycling compressor, a scenario analysis revealed that the deployment of an optimised system consisting of a fixed-speed baseload compressor and a variable-speed trim compressor can reduce the plant's energy consumption for the compressed air system by a significant 73%. This results in annual energy savings of 74,160 kWh, annual cost savings of €9.373,8, and an annual reduction of approximately 49,9 tonnes of carbon emissions. This application requires an initial investment of €24.280 and is anticipated to redeem itself in 2,2 years. Moreover, it is anticipated to generate a net present value of €147.602 over its 20-year lifespan.

Optimization mathematical model of a contact air cooler for a mine turbocompressor

Purpose. Establishing the dependencies of rational parameters of turbocompressor contact air coolers on the operating mode and initial conditions. Methodology. The methods of analytical research, mathematical modeling, physical modeling, and mathematical statistics were used in the study. Findings. As a result of the research, an optimization mathematical model of the mine turbocompressor air cooler was developed, which allows establishing its rational parameters depending on the initial conditions and operating modes of the turbocompressor. The adequacy of the theoretical studies was proved on a specially designed experimental setup. The obtained dependences make it possible to minimize the theoretical flow rate at the inlet to the uncooled section of the turbocompressor, which reduces the specific energy consumption for the compressed air production. Originality. For the the first time, a method has been developed for determining the rational parameters of contact air coolers when the initial temperature of water, air, and air pressure changes, which allows developing a methodology for the constructive calculation of the contact cooling system of mine turbocompressors. Practical value. Compressed air is widely used in all industries. It is one of the most common energy carriers in industrial enterprises, and the devices associated with its distribution and processing are an energy-intensive complex industrial energy system; the level of its perfection depends on the performance of technological processes that use compressed air. Compressed air is widely used in the mining industry (ore mining and fuel production). Compressed air is produced by turbocompressors. To increase the efficiency of the compressor, compressed air coolers are used. A significant weakness of the standard compressor cooling system is the rapid contamination of the heat exchange surfaces of air coolers with scale layers, which leads to a decrease in their efficiency and an increase in the specific energy consumption for compressed air production. This disadvantage is not found in the Venturi tube – centered droplet separator contact air coolers. As a result of the study, the dependencies were obtained and used to develop a methodology for the constructive calculation of contact air coolers for a mine turbocompressor.

TEMPERATURE OF THE COMPRESSOR SUCTION AIR AND ITS INFLUENCE ON THE EFFICIENT OPERATION OF THE COMPRESSOR UNIT

The climatic conditions of Uzbekistan are characterized by relatively long summers with air temperature of 40-45 0C and higher, which is the reason of significant heating of air suctioned by compressor. Increase in temperature and corresponding decrease inair density contributes to 8-10% decrease in compressor unit productivity, leading to significant economic losses in the process of compressed air production. By means of artificial cooling of suction air at the inlet to the compressor unit it is possible to increase the energy efficiency of operation of the mine reciprocating compressor unit.The effectiveness of artificial air temperature reduction depends on the amount of temperature reduction and the type of plant drive, as well as on the purpose -toreduce the specific electric energy consumption for compression or to increase the capacity of the reciprocating compressor.

Monitoring The Quality of a Reverse Osmosis System in The Energy Systems of The Milk Processing Plant

The objective of the present work is to monitor and control the physicochemical quality of the osmosis water that feeds the dairy industry in our case the power plant, specifically in terms of energy services. The three energy installations fed by reverse osmosis water are the boiler room, the cold room and the compressed air. These facilities respectively allow the production of steam, the absorption of heat from water through ammonia and the production of compressed air. During a period of 30 days, we monitored the pH, conductivity, alkalinity, hydrometric title, and chlorine content on water samples at the feed tank, boiler, and condenser. The results of the majority of the experimental analyzes comply with the standards imposed except for a few days.

A Case Study on Sustainable Production and Use of Compressed Air in European Industrial Sites of Medium-sized

Due to the urgency in climate change, the industry is mobilized to reduce its greenhouse gases. Compressed air represents nearly 10% of electricity used in industry. The research was carried out in an industrial food site in Europe. This research includes a case study and gives a specific approach and methodology to optimize environmental and economic impact of compressed air production and uses in an industrial site. The installation of this case study contains different type of compressed air, dryers, and filters. Each equipment has been subject to specific monitoring and analysis. Several actions have been identified for reducing carbon emissions by 69 tons such as: reduction of the compressed air pressure of the system, isolation of packaging lines when they are not running, implementation of pumps for vacuum generation on packaging lines, installation of smart management device and a heat recovery system. Financial savings are around 44 000 euros, and the average payback is below 3 years.

Improving the efficiency of mine compressor units based on the improvement of their cooling system

Resource saving is one of the most important problems in the world, including for such an energy-intensive process as the operation of mining compressor units. In the mining industry, along with electrical energy, pneumatic energy or compressed air energy is widely used. Compressor units that generate this energy are the most energy-intensive equipment of the enterprise, the share of which in the balance of mining enterprises is 20-35%. The indicators of technological processes of mining enterprises depend on the level of perfection of compressor installations. Given the widespread use of compressed air, there is a need to reduce operating costs, based on the development of effective technical solutions in the production of compressed air in industrial enterprises The tasks associated with increasing the energy efficiency of the operation of compressor units have not been fully resolved.

Investigation of Technical Feasibility of Hybrid Compressed Air Cogeneration Systems under Energy-Flexible Operation

The study investigates the effects of energy-flexible operation of hybrid compressed air systems in production processes with a view to efficiency and energy consumption. As energy costs become increasingly important in the economic considerations of industrial companies, integrating renewable energies necessitates the implementation of demand-side management capabilities to overcome the problem of intermittent energy production. One promising solution is hybridization, enabling energy systems to utilize multiple forms of energy. In the context of hybrid compressed air systems (CAS), it enables the use of gas, for example natural gas, hydrogen gas or biogas, and electricity for compressed air production, thus substituting electricity or gas demand on short- and long-term horizons. Advantages of such systems include the provision of energy flexibility as well as the variable supply of compressed air, process heat, and electricity through recuperation in the electric motor according to production plant consumption. However, the effects of energy-flexible operation on energy consumption and thus on the system's efficiency still needs to be fully understood. To this end, a demonstrator of a hybrid CAS cogeneration plant was built. Specific scenarios are used to analyze the effect on energy efficiency and the feasibility of energy-flexible operation. Despite slight reductions in efficiency during operation, the feasibility of operation was validated and valuable insights on further improvement were gained. With a view to the expected rising volatility in energy production, the hybrid approach represents an efficient, climate-friendly, energy-flexible, and resilient solution for compressed air production that could assist in expanding industrial demand-side management.

Operation of the compressed air production installation with variable air consumption

This paper presents an analysis of operation the compressed air production installation under the given operating conditions on an example of conceptual solution for the process air supply to a filter press of the Filtration Facility in the Copper Mine Majdanpek. Calculation was made using an analytical method for the installation operation with variable air consumption. Also, this paper presents a layout of technological scheme of the process air supply to the filter press, as well as the technical characteristics of compressed air production installation.

Experimental research on influence of interstage oil injection in a dual-motor-driven two-stage screw air compressor

Energy saving for compressed air production is of great importance all over the world due to its great energy cost and the indispensable utility of compressed air in the industrial sector. In recent years, oil-injected two-stage screw air compressors, especially driven by dual motors, are becoming a promising alternative to other compression equipment for their extraordinary efficiency and high reliability in a wide range of applications. However, two-stage screw air compressors have a different and complicated oil injection system compared with single-stage compressors. And an appropriate setting of oil injection parameters might result in a considerable performance improvement of the compressor. In this paper, a dual-motor-driven two-stage oil-injected screw compressor was tested under the actual service conditions and control modes experimentally. The effect of interstage oil injection on the compressor performance was studied in detail by varying the interstage oil injection flow rate and rotating speed. The performance parameters such as specific power, volumetric efficiency and adiabatic efficiency were calculated from the measured data. The results indicate that an excess amount of oil exists in the second stage compressor and reducing the oil moderately could decrease the power consumption of the two-stage air compressor unit.

Gas absorption in a hydraulic air compressor. Part I: Simultaneous hydrodynamic and mass transfer bubbly flow model

The formulation of a one-dimensional model for the simultaneous evaluation of hydrodynamics and mass transfer in bubbly flow is presented in detail. The mass transfer due to the solubility kinetics and psychrometric aspects of the process is evaluated while accounting for the effects of process temperature and salinity of the liquid phase. While developed for downward co-current bubbly flow, the predictions of the model show good agreement with experimental data found in the literature for co-current upward bubble column. Using the model, the predicted profiles of pressure, temperature, liquid velocity, slip velocity, species’ gas-phase molar flow rate along the axis of the pilot HAC downcomer under selected scenarios are presented. Modelling of the pilot and demonstrator scale HAC downcomers suggest that the psychrometric aspects of the compression process will be the determining factor for selecting HAC operating temperatures. Modelling of gas absorption in aqueous electrolyte solutions suggest that an intent to reduce gas solubility may be defeated due to the reduction of bubble size and the resulting increase in interfacial area. Initialisation of liquid phase concentrations of gas species are discussed with simulations showing the diminishing absorption rate with repeated cycles of gas compression when no gas is removed. The potential impacts on the applications of compressed air production and carbon capture are also discussed.

Regression analysis of the operational parameters and energy-saving potential of industrial compressed air systems

The electricity consumption of compressed air (CA) production and utilisation systems is high, due to an absence of suitable recovery methods and proper measurements in most industrial plants. This situation results in high costs of production and reduced profits. In our study, we therefore investigate the energy-saving potential of a CA system with the aim of reducing electricity consumption in an industrial facility. Our study consists of two parts: in the first stage, we evaluate the applicability of methods such as elimination of leakage in distribution lines, loaded-unloaded operation of compressors, and the use of waste heat recovery system methods, both physically and economically, while in the second, we examine the correlations between leakage airflow rate, noise, and system pressure in a general CA system and carry out regression analyses, using the SPSS (Statistical Package for Social Sciences) software program, for the first time. Our results suggest that optimised and improved CA systems are energy-saving solutions when applied in industrial plants. We demonstrate that there are strong correlations between the system pressure, air leakage diameter, noise, and annual leakage cost in industrial CA systems. The relationships between these variables can be expressed as a power model (Y=β×Xn).

Monitoring of compressed air losses in branched air flow networks of mining enterprises

Compressed air as a type of safe technological energy carrier is widely used in many industries. In economically developed countries energy costs for the production and distribution of compressed air reach 10 % of the total energy costs. The analysis of compressed air production and distribution systems in the industrial sector shows that the efficiency of the systems is at a relatively low level. This is due to the fact that insufficient attention is paid to these systems since the compressed air systems energy monitoring has certain difficulties – the presence of complex and branched air pipeline networks with unique characteristics; low sensitivity of the equipment which consumes compressed air; the complexity of auditing pneumatic equipment that is in constant operation. The article analyzes the options for reducing the cost of production and compressed air distribution. One of the promising ways to reduce the compressed air distribution cost is timely detection and elimination of leaks that occur in the external air supply network of the enterprise. The task is solved by hardware-software monitoring of compressed air pressure at key points in the network. The proposed method allows real-time detecting of emerging air leaks in the air duct network and sending commands to maintenance personnel for their timely localization. This technique was tested in the industrial conditions of ALROSA enterprises on the air pipeline network of the Mir mine of the Mirninsky Mining and Processing Plant and showed satisfactory convergence of the calculated leakage values ​​with the actual ones. The practical significance of the obtained results is that the developed method for monitoring air leaks in the air duct network is simple, it requires an uncomplicated software implementation and allows to localize leaks in a timely manner, thereby reducing unproductive energy costs at the enterprises.

Management of compressed air production at an industrial enterprise according to technical and economic criteria

The article is about development of mathematical model for the compressor management system of the enterprise station. The vector quality criterion consists two scalar objective functions. The first objective function characterizes the losses of the compressed air consumers of the enterprise. The second objective function characterizes the cost of electricity by compressors. The production task is solved periodically every 30 minutes as part of the automated process control system of the enterprise. The controlling influences are the composition and performance of the compressors.

IMPROVEMENT OF THE LABORATORY STAND FOR EXAMINATION OF THE PISTON COMPRESSOR AT THE EXPENSE OF THE PRESSURE CONTROL CIRCUIT ON THE BASIS OF THE PROGRAMMED LAMP! 12/24 RC IN MATLAB SIMULINK ENVIRONMENT

It is impossible to imagine any modern mechanism in any field of technology that has not been driven by an automated electric drive. In the electric drive, the main element that converts electrical energy into mechanical energy is an electric motor, which is controlled by converters and control devices in order to form static and dynamic characteristics of the electric drive that meet the requirements of the production mechanism. Equipment for the production and use of compressed air is universal and safe, it is widely used in modern industry. Compressed air is used as a source of energy, a medium for cleaning (purging), a means of transportation and even as a source of cold. Air compressors make up more than 80% of the total compressor fleet. Compressed air production and distribution systems in industry consume up to 10% of electricity. Unfortunately, there is an opinion that compressed air is cheap, although only 5-10% of the consumed electricity is spent on useful mechanical work. The cost of producing compressed air is 5-15% of the cost of production, and for some industries reach 30% or more. Reciprocating, centrifugal, and in recent years screw compressors have been widely used as air compression machines. In agricultural production, compressors are used to supply air and gases of the main or by-products of the technological cycle. These machines are common in gas supply systems. Compressors are also widely used in gas turbines. The laboratory stand for research of the piston compressor is modernized. On the basis of technical and economic indicators the electric drive system is selected, the electric motor is calculated and selected, it is checked with heating, overload capacity and start-up conditions, characteristics in statistical and dynamic modes are investigated, and also electric schemes of SAEP of the main lifting mechanism are developed. To verify the correctness of the adopted design methods, modeling was performed in Matlab.

Investigation of compressed air losses on production cost for Mosul dairy factor

A realistic field study was conducted on compressed air production stations in the Mosul Dairy Factory / Iraq, to determine the quantities of field losses resulting from the production of compressed air in the factory, and to determine the effect inlet temperature, pressure ratio, electric motor and leakage in the production line on the production cost, as all data were taken from the factory, and preparing a mathematical program to find and calculate the leaks in the compressed air in all parts of the factory production line. In addition to that the total cost of the compressed air losses during the production line was calculated. The results were listed in the form of quadrants that determined the relationship of the variables to losses in the production line. The typical lifetime compressed air costs in the year had been calculated and the percentage of each of the previous effects in the calculation of the saved cost, the results shows that the amount of the leakage, electric motor efficiency, intake temperature, and the reducing of setting pressure is about 16%, 54%, 25% and 5% respectively. This work leads us to another future work in which how to address these losses in compressed air in the factory production line and work to reduce them by technical means in order to reduce the cost wasted due to these losses.

Using a heat pump at the complex of energy generation and compressed air production for mining companies

A further efficiency upgrading of thermal power plants and boiler units at mining companies is linked to increasing the initial parameters of steam. Modern power units can work with an efficiency of 55-58%. However, it is possible to make a review of additional possibilities of heat utilization at a thermal power station. It is quite possible to increase the efficiency by 2-3% more due to the heat regeneration both in this cycle and in the water treatment units. A technology has been developed that combines the ORC and the cycle of compressed air production in a single power engineering system using an improved thermal-transformer, specifically, a refrigeration-heating machine what works in thermal networks of a thermal power station. In addition, from a practical point of view, it is shown that the efficiency of thermal power plant can be improved in comparison with standard schemes. Use of heat pumps beyond heating systems of private houses is becoming increasingly common in centralized heating systems and with feed water of thermal power plants. It significantly reduces the cost of heat and electricity production. Besides, solar collectors can integrate very well into the technological scheme of heating network water at the thermal power plant.

Energy management of compressed air systems. Assessing the production and use of compressed air in industry

The use of compressed air in industry is an important and yet overlooked energy carrier. Although there are different energy-saving measures discussed in the specialized literature, there is little discussion on the energy performance of the production and use of compressed air. This study developed a new approach to assess the energy performance of compressed air systems based on a six-step local energy benchmarking methodology. The methodology includes an energy management procedure to monitor and control the electricity consumption and sustain the energy performance of compressed air systems in time. The procedure monitors the production and use of compressed at plant and at manufacturing section levels based on the real-time monitoring of relevant variables to calculate energy performance indicators, energy baselines, and CUSUM charts. Monitoring the consumption of compressed air at the section level in a case study reduced the demand between 11 and 47%. While electricity consumption to produce compressed air at the plant level reduced by an estimated 23%. This approach permits the rapid detection of inefficiencies in the production and demand sides of the compressed air system, highlighting inefficiencies that are frequently hidden in the total electricity consumption of manufacturing plants.