Development of a sustainable pneumatic monitoring and control system

Abstract

This study focused on presenting a detailed evaluation of a Pneumatic Monitoring and Control System (PMCS) designed to save 30% of the compressed air consumption during a lifetime of 10 years. Compressed air is known to be an energy-intensive utility, and its optimisation is essential for enhancing energy efficiency and reducing operational costs. This project aimed to build upon a previous study, where it was found that although the PMCS is environmentally feasible, it is not financially feasible, and hence, further studies had to be performed concerning this aspect. The main objective of the project was to reduce the Financial Payback Period (FPP) of the PMCS, previously calculated at over 26 years, to a more feasible target of under 10 years, while also evaluating the environmental benefits using Life Cycle Assessment (LCA) methodology. A structured methodology following the DMAIC framework was adopted, including a comprehensive review of existing costs, implementation of cost-saving design modifications, and operational scenario analyses. Case studies involved the removal of high-range flow sensors, simplification of pneumatic assemblies, and reduction of housing size. Additional assessments evaluated the impact of scaling the number of Data Collection Points (DCPs), varying compressed air flow rates, and operating under different electricity tariffs. Results showed that through the combined implementation of the best design and operational scenarios, the FPP was reduced to approximately 8.7 years, demonstrating significant economic improvement. Environmental performance was assessed using SimaPro and the ReCiPe 2016 method, focusing on the Global Warming Potential (GWP), biodiversity impact (species. yr) as well as human health impact (DALY). The Environmental Payback Period (EPP) consistently remained below two months, even in scaled-up configurations. Overall, the findings confirm that the enhanced PMCS design is both financially and environmentally viable for wider industrial deployment, especially in energy-intensive applications where compressed air optimisation can offer measurable long-term benefits.