Filtration Technology in Compressed Air System

Did you know that compressed air is the third most common energy source in the industry?

airIn Europe 10% of industrial electricity consumption is to produce compressed air (80 terawatt hours).

Compressed air is one of the most expensive energy sources and it has only 15 % overall compressed air system efficiency. 

Based on specific application requirements it is necesary to reduce content of solid particles, water and oil to acceptable level.

Here is an exapmle. The findings of review of the secondary side of the compressor station (dryers, microfiltration):
  • Existing dryer '93 is equipped with a cooling media R 22, thus the maintenance of the cooling circuit can not be carried out in accordance with the Regulation on the use of ozone-depleting substances and fluorinated greenhouse gases.
  • Existing dryer is faulty - high dew point.
  • Existing filters for compressed air do not meet the capacity of the current capacity of the compressed air. Consequently, the pressure drop of up to 2 bar is occurring.
  • Leakage of air through each condensate drain, which are mounted on filters for compressed air
  • Implementation of system upgrades (additional dryer) has been carried out with a huge number of bends and T-pieces on the pipeline, which generates resistances in the system and the pressure drop.
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Proposal for a reconstruction:


To ensure the optimum quality of the compressed air system a new dryer with nominal capacity of 45 m3 / min, and a 3-stage filtration of compressed air with a level-controlled condensate drains without air loss has been envisaged.
The condensate, which is eliminated in the drying and microfiltration phase is connected to a condensate line, which is connected to the oil-water separator in which discharges condensate into the sewer, oil is filtered with PP filter.

Equipment used for the reconstruction:

1. For the compressor station:
  • Refrigerator dryer OMD 2600
  • The prefilter with differential pressure gauge and condensate drain type BF0300P / ECD90-B / MDA60
  • Microfilter with differential pressure gauge and condensate drain type BF0300M / ECD90-B / MDA60
  • Microfilter with differential pressure gauge and condensate drain type BF0300S / ECD90-B / MDA60
  • Water / oil separator from condensate: type WOS 35 (2 pcs)
  • For monitoring: Dew point sensor OS 220 and multifunction measuring instrument OS 331
2. Local Air treatment: technology for deposition of zinc capacitors (this is the customer's main product)
  • Heatless regenerated adsorption dryer B-DRY 600
  • For monitoring: The dew point sensor OS 220

TOTAL COST WITH SUPPLY AND INSTALLATION: 38.632,00 EUR

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The customer is still using the old compressors, which have a great potential for savings (frequency regulation technology, power transmissions, lower energy consumption, etc.). Reconstruction has been carried out only on the side of the compressed air treatment - drying and filtration. 

ENERGY SAVINGS:

Due to the smaller pressure resistors (new dryers, more efficient filters, no unnecessary knees on the installation of the pipeline) a preselection target pressure is reduced from 8.5 bar to 7 bar, which is approximately 9% lower energy consumption of screw compressors:
  • First: installed engine power of 110 kW
  • Second: installed engine power of 132 kW
  • Third: installed engine power of 132 kW
Factory works 24h / day, compressors annually carry 8,760 working hours and consume 3.291.200 kWh. The savings are 296.208 kWh annually.


If the price of electricity is 0,1 EUR/kWhANNUAL SAVING AMOUNT IS 29.620,80 EUR.


It is also crucial to have better air quality, which ensures longer life of pneumatic components on the production lines. It is difficult to evaluate how much the customer will save on the maintenance of pneumatic elements (cylniders, seals, valves, ...) on the production lines.


WHEN DESIGNING COMPRESSED AIR SYSTEM…

… we must consider specific end user or process requirements
… we follow ISO 8573-1 (Recommended quality clases according to ISO 8573-1)
… we follow principle „As much as necessery, as little as possible“

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