Utilisation of a compressed air test bed to assess the effects of pneumatic parameters on energy consumption

Abstract

In the manufacturing industry, pneumatic powered components provide a safe and reliable opportunity to automate a production line. However, compressed air systems are notoriously expensive to operate as a result of system losses and inefficiencies. Typical systems have an output efficiency of 10–12%. This offers a significant improvement opportunity to meet sustainable targets concerning energy consumption in industry and lower life cycle energy impacts. Amongst various inefficiencies, leakages and excessive pressures are identified as some of the most common sources of waste. The scope of this study was to make use of a compressed air system which was designed in the form an experimental test bed in order to assess the sustainability impact of various compressed air shortcomings. Simulations were carried out under experimental conditions to measure the additional energy consumption and air volume required for different pneumatic scenarios. Some of the results showed that a noise level of 70 dB is attributable to a leakage of 1.5 mm at the industry standard of 6 bar. Such a single leak could incur more than €470 of additional electrical costs and would result in 1.8 tonnes of additional carbon dioxide emissions within one year of operation, highlighting a significant effect on the life cycle impacts of industrial production.