Scope of Energy Saving in Pneumatics

Save Energy Save The EnvironmentEnergy conservation is something we are hearing more and more of with each passing day. With rising energy costs and depleting energy resources, it has become imperative that all of us start taking steps to conserve energy very seriously. In India, we are not able to produce enough energy to meet our demand. The most economical way to counter energy shortage is to conserve energy. It is estimated that India’s industrial sector has an energy conservation potential of around 35-45% (Source - Energy conservation in simple words means to get a similar output while reducing the input energy required.

Well, If we talk about Pneumatics industry we can follow a couple of simple steps to promote energy saving in the plant

  • Identify the potential areas for improvement - Internal studies conducted by SMC show that typical industrial units follow the following compressed air usage pattern – 10% for actuators, 20% lost as leakage and 70% for air blow applications as shown in the graph below. Energy Savings can be done all 3 areas, however, Air Blow applications and leakage losses have major scope of improvement.

                                          Energy Saving Chart

  • Quantify the losses – Calculate the amount of money you are using for compressed air consumption and the amount you are losing directly to leakages.

Calculations will typically use these values:

  • 8,760 hours of operation (24 hours/day x 365 days/year)
  • 85% electrical motor efficiency (0.85)
  • 4 CFM per BHP (Brake Horsepower)
  • Rs.6 per Kw hour (average INR estimate)

Annual Cost for compressed air generation = (BHP x 0.746 x Hours of Operation x Cost per kWh)/Motor Efficiency

For a 2000HP compressor,

                                            Annual Cost = (200 x 0.746 x 8760 x 6)/0.85

                                                                = Rs. 92,25,826

Therefore, potential estimated savings by reducing air leakage by 50% = (9225826 x 20%) x 50%

                                                                                                                = Rs. 9,22,582.6

  • Take measure to control the air consumption of the plant

There are a few measures which you can take for efficient energy utilization in the plant.

  • Air pressure should be at the minimum required level
  • Pneumatic components should be sized as per the actual performance need
  • Prepare the compressed air in an appropriate way
  • Use energy efficient products wherever possible
  • When not in use, isolate the plant with the help of 2 port valves
  • Stop air blow when not needed
  • For better efficiency, use multi-stage ejectors with vacuum switches
  • Keep a check on air consumption in the plant
  • Minimize air leaks

SMC has come up with Energy Saving Solutions for various applications in Pneumatics. Some of the Energy Saving Solutions are-

  • Air Saving Valves - Air Saving Valves Series ASR/ASQ reduce the air consumption by operating return- stroke side of an air cylinder at a reduced pressure. Pressure regulation is done with the help of a Regulator with a backflow function. To know more about ASR/ASQ valves, kindly follow the link
  • 3/4/5 Port Solenoid Valves - Energy-saving Model of SY series valves can reduce the power consumption by approximately 1/3 by reducing the wattage required to hold the valve in an energized state. Energy-saving valves Series SY with power saving circuit consumes only 0.1W of power as compared to the conventional model which consumes 0.55W. To know all about these valves, follow the link
  • Coolant Valves -  Low Power Consumption, High Flow Type Coolant Valves SGC Series reduce the coolant blow energy consumption by - 1. Reducing the pressure loss of the coolant which is done by making the effective area in the upstream side larger & attaching a nozzle; 2. Applying intermittent blow as the machine bed washing is topped when blowing for cutting or jig by means of a valve. The power consumption of these valves can be as low as 0.35 W (at 24 VDC). To know all about SGC Series Valves, follow the link

For more insight on SMC Energy Saving program and products, download the catalogue given below-

SMC's Energy Saving Solutions