Compressed AIr
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01 Basics of Compressed Air A - Introduction & Applications Product Line Training Product Line - Industrial Filtration Technology Status: July 2010
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Transcript of Compressed AIr
01 Basics of Compressed Air A - Introduction & Applications
Product Line Training
Product Line - Industrial Filtration Technology
Status: July 2010
2
Content
• History• Advantage• Costs• Applications
3
HistoryThe first known compressor…
Technical Data:Compressor: Membrane typePressure Rate: ≈ 0,02 – 0,08 barVolume Flow: ≈ 6 m³/hSpecial features: Excellent reliability
Min. maintenance required
…with limited application spectrum.
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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
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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
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Content
• History• Advantage• Costs• Applications
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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)
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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
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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
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Content
• History• Advantage• Costs• Applications
11
Costs
%100elP
mechP %100
PP
comp
el
Electrical Energy Mechanical Energy Compressed Air Mechanical Energy
%100PP
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!
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Energy73%
Investment19%
Cooling water
1%
Maintenance7%
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
CostsUp to 50% potential savings by leakage detection
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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,-€
CostsCosts of Compressed Air Leakages
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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
CostsCosts of Differential Pressure
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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]
Add
ition
al a
nnua
l ene
rgy
cost
[Eur
o]
110 kW
75 kW
45 kW
30 kW22 kW
11 kW
Inst
alle
d P
ower
CostsCosts of Differential Pressure
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Content
• History• Advantage• Costs• Applications
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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 airAs 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
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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
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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
