Compressed Air System

Compressed air is used widely throughout industry and is often considered the “fourth utility” at many facilities. Almost every industrial plant, from a small machine shop to an immense cement, minerals, power, pulp, paper mill and all the other industries, has some type of compressed air system. In many cases, the compressed air system is so vital that the facility cannot operate without it. Plant air compressor systems can vary in size from a small unit of 5 horsepower (hp) to huge systems with more than 50,000 hp.

In many industrial facilities, air compressors use more electricity than any other type of equipment. Inefficiencies in compressed air systems can therefore be significant. Energy savings from system improvements can range from 20 to 50 percent or more of electricity consumption. For many facilities this is equivalent to Lakhs, or even Crores of potential annual savings, depending on use. A properly managed compressed air system can save energy, reduce maintenance, decrease downtime, increase production throughput, and improve product quality.

Compressed air systems consist of a supply side, which includes compressors and air treatment, and a demand side, which includes distribution and storage systems and end-use equipment. A properly managed supply side will result in clean, dry, stable air being delivered at the appropriate pressure in a dependable, cost-effective manner. A properly managed demand side minimizes wasted air and uses compressed air for appropriate applications. Improving and maintaining peak compressed air system performance requires addressing both the supply and demand sides of the system and how the two interact.

Components of an Industrial Compressed Air System

A compressor is a machine that is used to increase the pressure of a gas. The earliest compressors were bellows, used by blacksmiths to intensify the heat in their furnaces. The first industrial compressors were simple, reciprocating piston-driven machines powered by a water wheel.

A modern industrial compressed air system is composed of several major sub-systems and many sub-components. Major sub-systems include the compressor, prime mover, controls, treatment equipment and accessories, and the distribution system.

The compressor is the mechanical device that takes in ambient air and increases its pressure. The prime mover powers the compressor. Controls serve to regulate the amount of compressed air being produced. The treatment equipment removes contaminants from the compressed air, and accessories keep the system operating properly.

Distribution systems are analogous to wiring in the electrical world—they transport compressed air to where it is needed. Compressed air storage can also serve to improve system performance and efficiency. Given Figure shows a representative industrial compressed air system and its components.