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A Review of Energy Overconsumption Reduction Methods in the Utilization Stage in Compressed Air Systems

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  • Dominik Gryboś

    (Department of Thermal and Fluid Flow Machines, Faculty of Energy and Fuels, AGH University of Krakow, Al. Mickiewicza 30, 30-059 Krakow, Poland)

  • Jacek S. Leszczyński

    (Department of Thermal and Fluid Flow Machines, Faculty of Energy and Fuels, AGH University of Krakow, Al. Mickiewicza 30, 30-059 Krakow, Poland)

Abstract

Pneumatic systems use the energy of compressed air to carry out manufacturing automation processes through the implementation of complex handling and motion tasks. However, these systems are energy intensive: it is estimated that pneumatic systems in manufacturing plants consume approximately 10% of all electricity consumed in the industrial sector. At the same time, the energy efficiency of the whole pneumatic system is observed to be 6–10%, due to the compression process, oversizing, and overconsumption. There are numerous solutions in the literature focusing on improving efficiency at the compression stage of utilization; however, for the utilization stage, there is a lack of systematization and grouping of these solutions. The following review will summarize current knowledge about the utilization stage and methods for improving oversizing and energy overconsumption. In addition, a method of exergy analysis for pneumatic systems will be presented, which is a very useful tool to assess the efficiency of these systems.

Suggested Citation

  • Dominik Gryboś & Jacek S. Leszczyński, 2024. "A Review of Energy Overconsumption Reduction Methods in the Utilization Stage in Compressed Air Systems," Energies, MDPI, vol. 17(6), pages 1-22, March.
    • Handle: RePEc:gam:jeners:v:17:y:2024:i:6:p:1495-:d:1361169
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    References listed on IDEAS

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    1. Leszczynski, J.S. & Grybos, D., 2019. "Compensation for the complexity and over-scaling in industrial pneumatic systems by the accumulation and reuse of exhaust air," Applied Energy, Elsevier, vol. 239(C), pages 1130-1141.
    2. Trianni, Andrea & Cagno, Enrico & Farné, Stefano, 2016. "Barriers, drivers and decision-making process for industrial energy efficiency: A broad study among manufacturing small and medium-sized enterprises," Applied Energy, Elsevier, vol. 162(C), pages 1537-1551.
    3. Andrea Trianni & Davide Accordini & Enrico Cagno, 2020. "Identification and Categorization of Factors Affecting the Adoption of Energy Efficiency Measures within Compressed Air Systems," Energies, MDPI, vol. 13(19), pages 1-51, October.
    4. Ryszard Dindorf & Jakub Takosoglu & Piotr Wos, 2023. "Review of Hydro-Pneumatic Accumulator Models for the Study of the Energy Efficiency of Hydraulic Systems," Energies, MDPI, vol. 16(18), pages 1-45, September.
    5. Benedetti, Miriam & Bonfa', Francesca & Bertini, Ilaria & Introna, Vito & Ubertini, Stefano, 2018. "Explorative study on Compressed Air Systems’ energy efficiency in production and use: First steps towards the creation of a benchmarking system for large and energy-intensive industrial firms," Applied Energy, Elsevier, vol. 227(C), pages 436-448.
    6. Cummins, Joshua J. & Nash, Christopher J. & Thomas, Seth & Justice, Aaron & Mahadevan, Sankaran & Adams, Douglas E. & Barth, Eric J., 2017. "Energy conservation in industrial pneumatics: A state model for predicting energetic savings using a novel pneumatic strain energy accumulator," Applied Energy, Elsevier, vol. 198(C), pages 239-249.
    7. Salvatori, Simone & Benedetti, Miriam & Bonfà, Francesca & Introna, Vito & Ubertini, Stefano, 2018. "Inter-sectorial benchmarking of compressed air generation energy performance: Methodology based on real data gathering in large and energy-intensive industrial firms," Applied Energy, Elsevier, vol. 217(C), pages 266-280.
    8. Qihui Yu & Jianwei Zhai & Qiancheng Wang & Xuxiao Zhang & Xin Tan, 2021. "Experimental Study of a New Pneumatic Actuating System Using Exhaust Recycling," Sustainability, MDPI, vol. 13(4), pages 1-14, February.
    9. Ryszard Dindorf & Jakub Takosoglu & Piotr Wos, 2023. "Review of Compressed Air Receiver Tanks for Improved Energy Efficiency of Various Pneumatic Systems," Energies, MDPI, vol. 16(10), pages 1-37, May.
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