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Pneumatic Conveying and Energy Efficiency in Pneumatic Systems

09 November 20175 min reading

“Since energy costs in pneumatic systems exceeded half of the total cost, pneumatic applications which are designed by considering efficiency and energy saving can recover initial investment costs in a short time. Our fundamental principle must be to prevent leakages and optimize pressure values.”

pneumatic conveyorTolga CANKURT Electromechanics and Robotics Director Hidropar Hareket Kontrol Teknolojileri Merkezi Sanayi Ticaret A.Ş.

Pneumatic conveyors are generally used for transferring substances in granular/powder structure by means of the air stream moving in a transmission line or transferring unit loads in private carriers. The common working principle of pneumatic conveyor machines is transferring the kinetic energy of the air stream.

Since air is a clean energy source and the system works in a completely enclosed environment, material losses and environmental pollution are minimized, and transfer operation is generally performed with zero loss.

Advantages of pneumatic conveyors compared to mechanical conveyors; • Installation and maintenance works are easy. • It provides flexibility to facilities. Transmission lines used in the systems adapt to plant layout easily and the possibility of working in a dust-free environment makes it easier to convey the material to almost all directions. • Material losses and environmental pollution are maintained at a minimum level during transfer operations. • It provides flexibility in transfer operations, materials can be conveyed from one point to another or several points. • It occupies less space compared to mechanical conveyors taking their carrying capacity into consideration. • Work safety is high. Industrial accidents are minimized since it is a closed system and personnel does not get into contact with mechanical transmission systems.

On the other hand, pneumatic conveyor systems have some disadvantages; • Energy consumption is high, • It is not possible to transfer all materials, • Initial investment costs are high,

Common pneumatic conveying methods;

• Condensed phase pneumatic conveying systems, • Sparse phase pneumatic conveying systems • Vacuum conveying systems.

ENERGY EFFICIENCY IN PNEUMATICS

There are many points where energy loss may occur within the system as compressed air is obtained and used. These losses may be prevented by means of a comprehensive energy saving precautions study, and energy consumption can be reduced significantly.

Since energy costs in pneumatic systems exceeded half of the total cost, pneumatic applications which are designed by considering efficiency and energy saving can recover initial investment costs in a short time.

Our fundamental principle must be to prevent leakages and optimize pressure values.

Three factors to consider for energy saving: SIZING

Accurate sizing of pneumatic components is a prerequisite for maximizing the efficiency of energy use. Choosing oversized components will increase energy consumption.

HOSE LENGTHS

As hose lengths increase, volume to be filled also increase accordingly. Not managing units from a single center can not only reduces the number of hose and connector components but also provides energy saving.

PRESSURE ADJUSTMENTS

Use the pressure commensurately. Maximizing the efficiency of pressure values is one of the smartest methods for energy saving.”

Why are we using large equipment to perform minor works?

Selection of correct structure sizes is one of the keystones for energy efficiency. Although significant efforts are made to achieve energy saving, it will not be possible to come up with the most efficient solution unless products which are specifically designed to meet your needs in the most proper manner are used. Since “the bigger the better” mentality is preferred in moments of hesitation, oversizing is among the common practices.

COMPACT COMPONENTS

Reducing cylinder diameters will help to decrease the required air volume level. Thanks to the use of more compact cylinders and valves, energy saving up to 15% can be achieved with compact and economic machine design.

Why are you creating unnecessary problems and complications with long hoses?

Save the air supply from being dependent on a single center. Central systems consume excessive energy due to long lines except that they are known for being unwieldy. Long lines connecting pneumatic panels to pneumatic driving components cause excessive pressure drops and energy losses. Use of cylinder-valve units will not only shorten hose lengths but also will reduce the number of connection points. Savings up to 35% can be achieved with cylinder-valve units. Pressure losses can be minimized with direct connection of cylinders and valves. In addition to this, cylinder-valve units have advantages such as easy installation and maintenance, quicker response times and higher cycle frequency.

Why are you causing redundant burdens with excessive energy?

Achieve energy savings with smart pressure adjustment. In case of low-pressure usage, necessary actions cannot be performed; and if excessive pressure is used, some part of the energy is wasted.

Energy savings up to 25% can be achieved through the accurate use of pressure for each application.

Electro-pneumatic pressure regulators can provide the precise pressure control required through combining digital control with innovative proportional technology.

Use pressure only in amounts required. Smart control systems continuously compare the current values with necessary values. In addition to this, cylinders may complement return strokes with lower pressure values.

Thanks to electro-pneumatic pressure control valves, cycles which do not require force can be performed at low pressures, and transition to necessary pressure values can be achieved in cycles that require force. It is possible to reach energy saving levels up to 25% by performing efficient pressure use.

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