IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v285y2023ics036054422302813x.html
   My bibliography  Save this article

Exergy analysis of pressure reduction, back pressure and intermittent air supply configuration of utilization/expansion stage in compressed air systems

Author

Listed:
  • Gryboś, Dominik
  • Leszczyński, Jacek

Abstract

Despite their many advantages, industrial compressed air systems are characterized by high energy consumption and very low energy efficiency. This is primarily due to the oversizing of pneumatic actuators, leading to excessive compressed air consumption in the utilization stage. Various methods have been proposed in the literature to address this issue, which can be classified into three groups: supply pressure reduction, back pressure increase, and intermittent power supply. However, no exergy analysis compares these methods in the utilization stage of a pneumatic system was performed. In this study, we conducted an exergy analysis to compare the exergy consumption and exergy savings of different pneumatic system configurations: the classic configuration, supply pressure reduction, back pressure increase, and intermittent power supply. The paper shows the most key places in CAS in terms of exergy losses, which result mainly from dead volumes, outlet loss and oversizing of components such as directional control valve, distributed pneumatic line and actuator. Losses in those components can amount to over 80% of input exergy and can be reduced even 3–9 times. Exergy evaluation of oversizing configurations showed that the highest exergy savings were obtained for a back pressure configuration (77%) and intermittent air supply (75%). The exergy savings for the pressure reduction configurations amounted to almost 50%. The paper presents mathematical models for several individual pneumatic components, including the actuator, directional control valve, muffler, pneumatic line and pressure reducer. The demonstrated mathematical model and exergy analysis can play a instrumental role in evaluating the exergy efficiency and optimization of a pneumatic system.

Suggested Citation

  • Gryboś, Dominik & Leszczyński, Jacek, 2023. "Exergy analysis of pressure reduction, back pressure and intermittent air supply configuration of utilization/expansion stage in compressed air systems," Energy, Elsevier, vol. 285(C).
    • Handle: RePEc:eee:energy:v:285:y:2023:i:c:s036054422302813x
    DOI: 10.1016/j.energy.2023.129419
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S036054422302813X
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2023.129419?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Cabello Eras, Juan José & Sagastume Gutiérrez, Alexis & Sousa Santos, Vladimir & Cabello Ulloa, Mario Javier, 2020. "Energy management of compressed air systems. Assessing the production and use of compressed air in industry," Energy, Elsevier, vol. 213(C).
    2. Leszczynski, J.S. & Grybos, D., 2019. "Compensation for the complexity and over-scaling in industrial pneumatic systems by the accumulation and reuse of exhaust air," Applied Energy, Elsevier, vol. 239(C), pages 1130-1141.
    3. Doner, Nimeti & Ciddi, Kerem, 2022. "Regression analysis of the operational parameters and energy-saving potential of industrial compressed air systems," Energy, Elsevier, vol. 252(C).
    4. Cummins, Joshua J. & Nash, Christopher J. & Thomas, Seth & Justice, Aaron & Mahadevan, Sankaran & Adams, Douglas E. & Barth, Eric J., 2017. "Energy conservation in industrial pneumatics: A state model for predicting energetic savings using a novel pneumatic strain energy accumulator," Applied Energy, Elsevier, vol. 198(C), pages 239-249.
    5. Vittorini, Diego & Cipollone, Roberto, 2016. "Energy saving potential in existing industrial compressors," Energy, Elsevier, vol. 102(C), pages 502-515.
    6. Brol, Sebastian & Czok, Rafał & Mróz, Piotr, 2020. "Control of energy conversion and flow in hydraulic-pneumatic system," Energy, Elsevier, vol. 194(C).
    7. Nehler, Therese, 2018. "Linking energy efficiency measures in industrial compressed air systems with non-energy benefits – A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 89(C), pages 72-87.
    8. Gładysz, Paweł & Stanek, Wojciech & Czarnowska, Lucyna & Węcel, Gabriel & Langørgen, Øyvind, 2017. "Thermodynamic assessment of an integrated MILD oxyfuel combustion power plant," Energy, Elsevier, vol. 137(C), pages 761-774.
    9. Salvatori, Simone & Benedetti, Miriam & Bonfà, Francesca & Introna, Vito & Ubertini, Stefano, 2018. "Inter-sectorial benchmarking of compressed air generation energy performance: Methodology based on real data gathering in large and energy-intensive industrial firms," Applied Energy, Elsevier, vol. 217(C), pages 266-280.
    10. Schudeleit, Timo & Züst, Simon & Weiss, Lukas & Wegener, Konrad, 2016. "The Total Energy Efficiency Index for machine tools," Energy, Elsevier, vol. 102(C), pages 682-693.
    11. Czopek, Dorota & Gryboś, Dominik & Leszczyński, Jacek & Wiciak, Jerzy, 2022. "Identification of energy wastes through sound analysis in compressed air systems," Energy, Elsevier, vol. 239(PB).
    12. Vittorini, Diego & Cipollone, Roberto, 2016. "Financial analysis of energy saving via compressor replacement in industry," Energy, Elsevier, vol. 113(C), pages 809-820.
    13. Szargut, Jan T., 2004. "Optimization of the design parameters aiming at the minimization of the depletion of non-renewable resources," Energy, Elsevier, vol. 29(12), pages 2161-2169.
    14. Leszczynski, J.S. & Grybos, D., 2020. "Sensitivity analysis of Double Transmission Double Expansion (DTDE) systems for assessment of the environmental impact of recovering energy waste in exhaust air from compressed air systems," Applied Energy, Elsevier, vol. 278(C).
    15. Saidur, R. & Rahim, N.A. & Hasanuzzaman, M., 2010. "A review on compressed-air energy use and energy savings," Renewable and Sustainable Energy Reviews, Elsevier, vol. 14(4), pages 1135-1153, May.
    16. Susanne V. Krichel & Oliver Sawodny, 2014. "Non-linear friction modelling and simulation of long pneumatic transmission lines," Mathematical and Computer Modelling of Dynamical Systems, Taylor & Francis Journals, vol. 20(1), pages 23-44, January.
    17. Dominik Gryboś & Jacek S. Leszczyński & Dorota Czopek & Jerzy Wiciak, 2021. "Exhaust Noise Reduction by Application of Expanded Collecting System in Pneumatic Tools and Machines," Energies, MDPI, vol. 14(6), pages 1-17, March.
    18. Massimo Borg & Paul Refalo & Emmanuel Francalanza, 2023. "Failure Detection Techniques on the Demand Side of Smart and Sustainable Compressed Air Systems: A Systematic Review," Energies, MDPI, vol. 16(7), pages 1-36, March.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Gryboś, Dominik & Młynarczyk, Dorota & Leszczyński, Jacek & Wiciak, Jerzy, 2024. "Mitigation of noise pollution in compressed air installations through the use of an air collection system in the expansion process," Applied Energy, Elsevier, vol. 364(C).
    2. Czopek, Dorota & Gryboś, Dominik & Leszczyński, Jacek & Wiciak, Jerzy, 2022. "Identification of energy wastes through sound analysis in compressed air systems," Energy, Elsevier, vol. 239(PB).
    3. Leszczynski, J.S. & Grybos, D., 2020. "Sensitivity analysis of Double Transmission Double Expansion (DTDE) systems for assessment of the environmental impact of recovering energy waste in exhaust air from compressed air systems," Applied Energy, Elsevier, vol. 278(C).
    4. Jan Markowski & Dominik Gryboś & Jacek Leszczyński & Yohiside Suwa, 2023. "Exhaust Air Recovery System from the Utilisation Stage of Pneumatic System in Double Transmission Double Expansion Approach," Energies, MDPI, vol. 16(23), pages 1-14, November.
    5. Massimo Borg & Paul Refalo & Emmanuel Francalanza, 2023. "Failure Detection Techniques on the Demand Side of Smart and Sustainable Compressed Air Systems: A Systematic Review," Energies, MDPI, vol. 16(7), pages 1-36, March.
    6. Leszczynski, J.S. & Grybos, D., 2019. "Compensation for the complexity and over-scaling in industrial pneumatic systems by the accumulation and reuse of exhaust air," Applied Energy, Elsevier, vol. 239(C), pages 1130-1141.
    7. Andrea Trianni & Davide Accordini & Enrico Cagno, 2020. "Identification and Categorization of Factors Affecting the Adoption of Energy Efficiency Measures within Compressed Air Systems," Energies, MDPI, vol. 13(19), pages 1-51, October.
    8. Cabello Eras, Juan José & Sagastume Gutiérrez, Alexis & Sousa Santos, Vladimir & Cabello Ulloa, Mario Javier, 2020. "Energy management of compressed air systems. Assessing the production and use of compressed air in industry," Energy, Elsevier, vol. 213(C).
    9. Dominik Gryboś & Jacek S. Leszczyński, 2024. "A Review of Energy Overconsumption Reduction Methods in the Utilization Stage in Compressed Air Systems," Energies, MDPI, vol. 17(6), pages 1-22, March.
    10. Fábio de Oliveira Neves & Henrique Ewbank & José Arnaldo Frutuoso Roveda & Andrea Trianni & Fernando Pinhabel Marafão & Sandra Regina Monteiro Masalskiene Roveda, 2022. "Economic and Production-Related Implications for Industrial Energy Efficiency: A Logistic Regression Analysis on Cross-Cutting Technologies," Energies, MDPI, vol. 15(4), pages 1-19, February.
    11. Hernan Hernandez-Herrera & Jorge I. Silva-Ortega & Vicente Leonel Mart nez Diaz & Zaid Garc a Sanchez & Gilberto Gonz lez Garc a & Sandra M. Escorcia & Habid E. Zarate, 2020. "Energy Savings Measures in Compressed Air Systems," International Journal of Energy Economics and Policy, Econjournals, vol. 10(3), pages 414-422.
    12. Nel, A.J.H. & Vosloo, J.C. & Mathews, M.J., 2018. "Financial model for energy efficiency projects in the mining industry," Energy, Elsevier, vol. 163(C), pages 546-554.
    13. Zhan, Changfeng & Yin, Yonggao & Jin, Xing & Zhang, Xiaosong, 2018. "Experimental and simulated study on a novel compressed air drying system using a liquid desiccant cycle," Energy, Elsevier, vol. 162(C), pages 60-71.
    14. Benedetti, Miriam & Bonfa', Francesca & Bertini, Ilaria & Introna, Vito & Ubertini, Stefano, 2018. "Explorative study on Compressed Air Systems’ energy efficiency in production and use: First steps towards the creation of a benchmarking system for large and energy-intensive industrial firms," Applied Energy, Elsevier, vol. 227(C), pages 436-448.
    15. Zhang, Yongyu & Gao, Ran & Si, Pengfei & Shi, Lijun & Shang, Yinghui & Wang, Yi & Liu, Boran & Du, Xueqing & Zhao, Kejie & Li, Angui, 2023. "Study on performances of heat-oxygen coupling device for high-altitude environments," Energy, Elsevier, vol. 272(C).
    16. Hongwang Du & Wei Liu & Xin Bian & Wei Xiong, 2022. "Energy-Saving for Industrial Pneumatic Actuation Systems by Exhausted Air Reuse Based on a Constant Pressure Elastic Accumulator," Sustainability, MDPI, vol. 14(6), pages 1-13, March.
    17. Dominik Gryboś & Jacek S. Leszczyński & Dorota Czopek & Jerzy Wiciak, 2021. "Exhaust Noise Reduction by Application of Expanded Collecting System in Pneumatic Tools and Machines," Energies, MDPI, vol. 14(6), pages 1-17, March.
    18. Stanek, Wojciech & Czarnowska, Lucyna, 2018. "Thermo-ecological cost – Szargut's proposal on exergy and ecology connection," Energy, Elsevier, vol. 165(PB), pages 1050-1059.
    19. Bumann, A.A. & Papadokonstantakis, S. & Sugiyama, H. & Fischer, U. & Hungerbühler, K., 2010. "Evaluation and analysis of a proxy indicator for the estimation of gate-to-gate energy consumption in the early process design phases: The case of organic solvent production," Energy, Elsevier, vol. 35(6), pages 2407-2418.
    20. Vittorini, Diego & Cipollone, Roberto, 2016. "Energy saving potential in existing industrial compressors," Energy, Elsevier, vol. 102(C), pages 502-515.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:285:y:2023:i:c:s036054422302813x. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.