Reduce 30%-50% Compressed Air Consumption for Drying & Blow-off Process, which can reduce the operating Cost & increase efficiency with performance
By: Puspendu Dhara
Tags: Innovation, Engineering, Manufacturing, Energy, Productivity

Reduce 30%-50% Compressed Air Consumption for Drying & Blow-off Process, which can reduce the operating Cost & increase efficiency with performance Puspendu Dhara Jan 16·4 min read

What is compressed air?

Compressed air is a form of energy storage due to its ability to perform work when decompressed. The production of compressed air is carried out, for the most part, with electric power by means of a compressor.

Where is compressed air used?

The vast majority of industrial companies use compressed air in some way or within some equipment, i.e. for surface drying or cleaning.

After assimilating the total cost of a compressed air system during its first 10 years of operation, it is understood that 73% comes from the electrical energy necessary for its operation. The rest of the costs includes the initial in- vestment, maintenance and installation costs.

The energy efficiency of a compressed air installation is very low, since of the total energy provided only.

between 8% and 10% becomes useful energy capable of performing a job. The rest is lost in compression, regulation, cooling, dehumidification and leakage in equipments and pipes.

In addition to the compressed air generated by the compression units, it is estimated that 50% is used in nonproductive demand components such as leaks, inappropriate uses of compressed air and artificial demand (excess of the level of air pressure at which our compressed air installation is adjusted above the actual values necessary for it to function properly).

How to reduce a system’s operating costs?

When it comes to saving on operating costs, there are several measures that can be taken. An installation can be divided into two fundamental parts: one is production, which includes compressors and air treatment; the other is demand, which includes distribution, storage systems and end-use equipment. The correct combination between production and demand leads to a decrease in costs.

There are several ways to make an installation more efficient and reduce its operating costs, such as energy recovery for other functions, pressure reduction, decrease in the number of leaks and optimisation of operations through a correct control and regulation system.

Chart of the various Operation Cost

Savings opportunities in a compressed air installation: Leak control

Installations can have different types of leaks, which can be prevented by performing frequent maintenance. An installation is considered to be in good condition when leaks constitute 10% of production

Compressor air intake control

For greater compressor performance, it is important that the sucked air is clean and cold. Since the specific volume of air depends on temperature, the colder it is, the more air fits in the compressor, thus improving its performance.

Inefficient applications

There are parts of the installation that are obsolete or whose operating cost could be reduced with a small investment. This is the case of air nozzles: using nozzles designed for each application instead of a tube increases system efficiency and cuts costs.

Air Nozzle Arrangement

Graphs with Compressed Air Savings Data of Ikeuchi Air Nozzles

using 1/4M TF-R 8–010 PP IN Nozzle we can save 35% Compressed Air

2. 1/4M CCP 2.5A S303 Nozzles can save 50% Compressed Air

1/4M CCP 2.5A S303 Nozzles can save 54% Compressed Air

Ikeuchis Energy Efficient Air Nozzles

It’s not about compressed air, It is about saving operation Cost

PUSPENDU DHARA

Sales Engineer

H.Ikeuchi & Co., Ltd, Japan

Contact number : +817036634478

Website:https://ikeuchiindia.in/