Aire Comprimido - Conceptos
Transcript of 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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
Compressed Air Energy
Inefficient power source even if well maintained
Eight compressorhorsepower
One horsepower ofcompressed air
}yields . . .
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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 . . .
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Supply compressor types
Compressors
Positive Displacement Dynamic
Reciprocating
Rotary
Centrifugal Axial
Single Acting
Helical Screw Scroll
Double Acting
Liquid Ring Sliding Valve
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Supply compressors
Reciprocating
Very efficient
Requires frequentmaintenance
Can be equipped for veryefficient part loading
Can be multistaged
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Supply compressors
Rotary Screw Easy to install
Enables modulationcontrol
Easy to maintain Can be single or doublestaged
Source: Gardner Denver
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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)
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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
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Efficient compressed air systems
Proper performance yields Low operating costs
Minimal downtime
Clean, dry, dependable air
Effective process control
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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
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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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
}8 compressor horsepoweryields 1 horsepower ofcompressed air . . .Heat recovery
Where does the other7 horsepower
go????
HEAT.HEAT.
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
Heat recovery
Compressor
Winter Operation
Hot air to
Plant
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US DOE Industries of the Future Workshop Series
Heat recovery
Compressor
Summer Operation
Hot air Exhausted
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
Pressure drop (continued)
Distribution
Worksheet Calculating the Cost of High Pressure
Drop
GOAL: 0 4 psigpressure drop incompressor room
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
Air Storage Compressor Loading
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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US DOE Industries of the Future Workshop Series
Air Storage Compressor Loading
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
Compressor controls
Using the Most Efficient Control Strategy worksheet
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US DOE Industries of the Future Workshop Series
Inappropriate End Uses
Anything that can be done More effectively by another method
More efficiently by another method
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
Application of new technologies/concepts
Variable speed compressors
Zero loss drains
Air amplifying nozzles
Solenoid shut off valves
Demand Controller
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
Electric Solenoid Valves
Reduce leaks in piping toequipment that is shut off
Timer control
Machine panel control
Manual control
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
How to start
Steps in evaluating your system
Monitoring needs
Best Practices
Pitfalls
Treat compressed air like a fourth utility.
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US DOE Industries of the Future Workshop Series
Monitoring
Air Pressure Problems
Compressor Loading
Power consumption
Air Consumption
Track using MS Excel or similar program
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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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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US DOE Industries of the Future Workshop Series
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/