Energy saving potential analysis of a short cycling industrial air compressor in a marine equipment manufacturing plant in Türkiye

IF 3.7 Q2 ENVIRONMENTAL SCIENCES
Eren Uyan
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Abstract

Compressed air systems are recognised as significant energy users and are characterised by their notably inefficient energy consumption. This ensures their significance and potential for decarbonisation through cleaner and more responsible energy consumption in manufacturing facilities, such as marine equipment manufacturing plants in the shipbuilding industry, in order to address the various economic and regulatory challenges related to energy use and climate change. In the relevant literature, there are numerous studies on various energy-saving measures for compressed air systems; however, none concentrates on the problem of short-cycling phenomena and associated energy-saving potential. In this study, using a novel and systematic energy audit methodology, a detailed energy audit of a rotary-type screw air compressor was conducted at a marine equipment manufacturing plant in Türkiye. The systematic energy audit methodology was based on the measurement of power consumption and the evaluation of various operation parameters to assess the existing performance of the compressor, including compressed air demand, compressed air production, cycle speed, air tank volume, specific capacity, and duty cycle. The audit results revealed that the air compressor was short cycling, resulting in excessive energy consumption. Comprehensive technical and economic assessments were conducted to determine the root cause of the compressor's short cycling and to identify energy-saving potentials. It was determined that the compressor was oversized relative to the plant's compressed air demand patterns, while the air tank was inadequately sized, causing the compressor to engage in short cycling. To replace the existing short-cycling compressor, a scenario analysis revealed that the deployment of an optimised system consisting of a fixed-speed baseload compressor and a variable-speed trim compressor can reduce the plant's energy consumption for the compressed air system by a significant 73%. This results in annual energy savings of 74,160 kWh, annual cost savings of €9.373,8, and an annual reduction of approximately 49,9 tonnes of carbon emissions. This application requires an initial investment of €24.280 and is anticipated to redeem itself in 2,2 years. Moreover, it is anticipated to generate a net present value of €147.602 over its 20-year lifespan.

浙江某船舶设备制造厂短循环工业空压机节能潜力分析
压缩空气系统被认为是重要的能源用户,其特点是能源消耗效率低下。这确保了它们通过制造设施(如造船业的海洋设备制造厂)中更清洁和更负责任的能源消耗来实现脱碳的重要性和潜力,以应对与能源使用和气候变化相关的各种经济和监管挑战。在相关文献中,对压缩空气系统的各种节能措施进行了大量研究;然而,没有一个集中于短循环现象的问题和相关的节能潜力。在这项研究中,使用一种新颖而系统的能源审计方法,对 rkiye的一家船舶设备制造厂的旋转式螺杆空气压缩机进行了详细的能源审计。系统的能源审计方法是基于对功率消耗的测量和对各种运行参数的评估来评估压缩机的现有性能,包括压缩空气需求、压缩空气产量、循环速度、空气罐容积、比容和占空比。审计结果显示空压机循环时间短,导致能耗过大。进行了综合技术经济评估,确定了压缩机循环周期短的根本原因,并确定了节能潜力。据确定,压缩机相对于工厂的压缩空气需求模式过大,而空气罐的尺寸不足,导致压缩机循环时间短。为了取代现有的短循环压缩机,方案分析显示,部署由定速基本负荷压缩机和变速调节压缩机组成的优化系统可以将工厂压缩空气系统的能耗显著降低73%。每年可节省74,160千瓦时的能源,每年节省9.373,8欧元的成本,每年减少约49,9吨的碳排放。该应用程序需要24.280欧元的初始投资,预计将在2,2年内赎回。此外,预计在其20年的寿命期内将产生147.602欧元的净现值。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Cleaner and Responsible Consumption
Cleaner and Responsible Consumption Social Sciences-Social Sciences (miscellaneous)
CiteScore
4.70
自引率
0.00%
发文量
40
审稿时长
99 days
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