Persluchtsysteem
Compressed air system solution
A compressed air system is an essential part of many modern production environments, from powering pneumatic tools in manufacturing to delivering sterile pressurized air in pharmaceutical settings. The systems are populair because they are clean, flexible and safe compared to other energy sources. However, compressed air systems are also known for being energy-intensive. That’s why it’s vital to choose the right air compressor system, built with reliable components such as rotary screw air compressors, air dryers, and air receiver tanks. Even a small optimization can lead to substantial energy cost savings and increased operational efficiency.
What is a compressed air system?
A compressed air system consists of components that compress, treat, store, and distribute pressurized air for industrial applications. A motor-driven air compressor draws in atmospheric air, compresses it to raise pressure, and sends it through air treatment components like air dryers and air filters to remove excess moisture, oil, and dust. The clean, dry air is stored in an air receiver tank (or storage tank) before being distributed via a piping network to various air tools, machines, or automated valves. Our compressed air systems include sensors, controllers, and feedback loops to maintain system pressure, reduce pressure drops, and prevent air leaks. Presscon’s PEC Controller plays a central role in optimizing these elements for energy-efficient operation.
Need advice about nitrogen purge?
Wanneer heb je een persluchtsysteem nodig?
Perslucht is een veelzijdig en veilig alternatief voor elektrische energie, vooral in industriële omgevingen. Het wordt vaak de vierde nutsvoorziening genoemd, na elektriciteit, water en aardgas.
Productie en automatisering:
Fabrieken gebruiken perslucht om pneumatisch gereedschap (zoals slagmoersleutels, boren, verfspuiten) aan te drijven, cilinders en robotaandrijvingen te bedienen, transportbanden te laten draaien en materiaal te verplaatsen. Persluchtgereedschap is vaak lichter en veiliger dan elektrische versies omdat perslucht geen risico op vonken bevat en continu kan werken zonder oververhitting.
Voedingsmiddelen, dranken en farmaceutica:
In deze sectoren wordt schone, droge perslucht gebruikt voor verwerking en verpakking. Voorbeelden zijn luchtstralen voor het snijden of pellen van producten, het mengen of roeren van vloeistoffen en poeders, het transporteren van voedingsmiddelen, het bottelen van dranken en het vacuüm sealen van verpakkingen. Omdat perslucht extreem schoon kan worden gemaakt (olievrij en gefilterd), is het ideaal voor gevoelige producten. Het levert bijvoorbeeld steriele lucht voor farmaceutische productie en handhaaft hygiënische omstandigheden in voedselverwerkingslijnen.
Gezondheidszorg en ademlucht:
Ziekenhuizen en klinieken vertrouwen op sterk gezuiverde perslucht voor beademingsapparatuur en ventilatoren, chirurgische instrumenten en tandheelkundige instrumenten.
Chemische en petrochemische industrie:
Perslucht is een veilige energiebron in ontvlambare of gevaarlijke omgevingen. Het drijft regelkleppen en instrumenten aan, belucht en mengt chemische mengsels en drijft pompen aan om vloeistoffen te verplaatsen.
HVAC- en bouwsystemen:
Grote commerciële gebouwen gebruiken perslucht in HVAC-regelsystemen (bijv. pneumatische thermostaten en klepactuators voor verwarmings-/koelingssystemen). Perslucht drijft ook de remmen aan in liften en pretparkattracties, en wordt gebruikt in sprinklersystemen of voor het pompen van afvalwater in gebouwen.
Belangrijkste persluchtsysteemcomponenten
Elk persluchtsysteem is gebaseerd op een aantal essentiële componenten die samenwerken om schone, droge en betrouwbare perslucht te produceren. Inzicht in deze componenten is essentieel om consistente prestaties te garanderen, stilstand te minimaliseren en de energie-efficiëntie van elk industrieel persluchtcompressorsysteem te verbeteren.
Deze componenten vormen de basis van een betrouwbaar en energie-efficiënt systeem. Wanneer ze op de juiste manier zijn geconfigureerd, zorgen ze voor een stabiele werking, verlagen ze de onderhoudskosten en verlengen ze de levensduur van uw apparatuur, zelfs in de meest veeleisende industriële omgevingen.
Luchtcompressor
De luchtcompressor is het hart van het systeem. De meeste installaties gebruiken schroefcompressoren of andere verdringertypes om omgevingslucht aan te zuigen en samen te persen tot de vereiste druk. Deze samengeperste lucht wordt vervolgens via leidingen geleverd om pneumatisch gereedschap, machines en geautomatiseerde processen van energie te voorzien.
Persluchttanks
Luchtketeltanks fungeren als buffer tussen de compressor en het distributiesysteem. Ze slaan perslucht op, verminderen drukschommelingen en helpen plotselinge pieken in de vraag op te vangen. De juiste grootte van de tanks zorgt voor een soepelere werking en zorgt ervoor dat compressoren efficiënter werken met minder start-/stopcycli.
Luchtdroger
Een luchtdroger verwijdert overtollig vocht uit perslucht om het vereiste dauwpunt (luchtdroogheid) te bereiken. Perslucht die uit de compressor komt is heet en verzadigd met waterdamp; als het afkoelt condenseert er water dat leidingen kan roesten en apparatuur kan beschadigen. Gekoelde drogers koelen de lucht om te condenseren en water te verwijderen, waardoor het dauwpunt meestal rond de 2-5°C (35-40°F) ligt. Drogers met droogmiddel absorberen waterdamp om nog lagere dauwpunten te bereiken (tot -40°F/C of droger) voor gevoelige toepassingen. Het verwijderen van vocht is essentieel omdat droge lucht corrosie en microbiologische groei in het systeem voorkomt.
Luchtfilters
Luchtfilters worden geïnstalleerd om oliedeeltjes, stof en andere verontreinigingen uit de afgevoerde lucht te verwijderen. Schone lucht beschermt downstream apparatuur en zorgt voor naleving van luchtkwaliteitsnormen, vooral in sectoren zoals voeding, farma en elektronica. Afhankelijk van de vereiste zuiverheidsgraad kunnen meerdere filterstadia worden gebruikt.
Bediening en instrumentatie
Drukschakelaars of elektronische regelaars starten/stoppen bijvoorbeeld compressoren of ontlasten ze om de doeldruk te handhaven; veiligheidskleppen beschermen tegen overdruk in tanks; en onze persluchtsystemen hebben centrale regelaars om meerdere compressoren te coördineren. Bewakingsapparatuur (drukmeters, dauwpuntbewaking, debietmeters) helpt bij een efficiënte werking van het systeem. Al deze componenten werken samen om ervoor te zorgen dat de perslucht wordt geleverd met de juiste druk, het juiste debiet en de juiste kwaliteit voor de beoogde toepassing.
Belangrijke parameters en dimensionering voor een persluchtsysteem
- Druk (PSI / bar): De vereiste systeemdruk hangt af van de specifieke toepassingen en de gebruikte apparatuur. De meeste industriële persluchtsystemen werken tussen 6 en 8 bar (87-116 PSI), hoewel sommige processen een druk buiten dit bereik vereisen. Werken op de laagste effectieve druk kan helpen het energieverbruik te verlagen; elke verlaging van 1 bar kan een energiebesparing tot 7% opleveren.
Tip: Overdruk leidt vaak tot onnodig energieverbruik. Drukregelaars en intelligente regelsystemen zoals de PEC Controller helpen om een evenwichtig drukniveau te handhaven.
- Debiet (CFM / l/s): Debiet wordt meestal uitgedrukt in CFM (Cubic Feet per Minute) of liter per seconde (l/s) en geeft de hoeveelheid lucht aan die nodig is om gereedschappen en machines te bedienen. Het totale vereiste debiet wordt meestal berekend door de vraag van alle aangesloten apparaten bij elkaar op te tellen, rekening houdend met hun gebruikspatronen en piekbelasting.
- Luchtkwaliteit en -zuiverheid: De vereiste luchtkwaliteit varieert per industrie.
– ISO 8573-1 Klasse 1 is over het algemeen nodig voor farmaceutische en voedseltoepassingen.
– Klasse 4 tot 6 is meestal voldoende voor algemene productie.
Filtratie- en droogsystemen moeten dienovereenkomstig worden geselecteerd om het gewenste dauwpunt te bereiken en olie, stof en vocht uit de luchtstroom te verwijderen. Grootte van luchtketel: Een persluchtketeltank helpt om de systeemdruk op peil te houden en schommelingen in de vraag op te vangen. Een algemene richtlijn is 3 tot 5 gallon tankinhoud per CFM compressorvermogen. De juiste grootte van de tank draagt bij aan een betere efficiëntie van de compressor en verlengt de levensduur van de apparatuur.
- Hoogte en omgevingstemperatuur: De efficiëntie van de compressor kan worden beïnvloed door omgevingsfactoren. Op grotere hoogten resulteert een lagere luchtdichtheid in een lager compressorvermogen. Verhoogde omgevingstemperaturen kunnen ook de prestaties en koelefficiëntie beïnvloeden. In dergelijke gevallen moet het systeem mogelijk worden aangepast of opgeschaald voor een optimale werking.
- Paardekracht (kW): Het vermogen van de compressor moet overeenkomen met de vereiste druk en het debiet. Een hoger vermogen betekent over het algemeen een hogere luchtopbrengst, maar ook een hoger energieverbruik. Met de PEC Controller van Presscon kunnen compressoren met verschillende vermogens (5kW, 25kW of 100kW) intelligent worden beheerd om te reageren op de werkelijke vraag.
- Drukverlies: Elk systeemonderdeel introduceert een zekere mate van drukverlies. De totale drukval onder 0,5 bar houden helpt om efficiënte prestaties te behouden. Filterbewaking en tijdige vervanging, in combinatie met een goed ontworpen leidinglay-out en de juiste leidingdiameter, kunnen helpen om drukverlies te minimaliseren en energieverspilling te verminderen.
Optimal size is the most energy efficient
Met de expertise van Presscon en de PEC Controller helpen wij u uw persluchtsysteem nauwkeurig te dimensioneren op basis van de werkelijke vraag, de toekomstige schaalbaarheid en uw specifieke industriële vereisten. Dit resulteert in:
- Lagere energiekosten
- Betere uptime van het systeem
- Betrouwbaarheid op lange termijn
Neem contact met ons op voor deskundig advies of een consult op maat.
How does the compressed air system solution work in practice?
In een persluchtnetwerk of compressorpark staan bijvoorbeeld compressoren van 2kW, 5kW, 25kW en 100kW. Stel dat de vraag naar perslucht zo groot is dat de drie compressoren met het minste vermogen de gevraagde hoeveelheid niet kunnen leveren. Een drukgestuurd systeem schakelt op dat moment alle vier de compressoren in het park in. Dit terwijl de 100kW compressor in zijn eentje ook in staat is om het gevraagde vermogen te leveren. De door ons ontwikkelde PEC Controller stuurt de compressoren aan op basis van flow. In deze situatie schakelt hij vanaf het begin alleen de 100kW compressor in. Voor u als bedrijfseigenaar is dit de meest energie-efficiënte keuze die voldoet aan de persluchtbehoefte.
Het grootste voordeel van debietregeling is de snelheid waarmee het systeem actie onderneemt, zodat het compressorpark rustig kan reageren. Dit resulteert in een optimaal energieverbruik.
De persluchtsysteemoplossing van Presscon: PEC-regelaar
In een persluchtnetwerk of compressorpark staan bijvoorbeeld compressoren van 2kW, 5kW, 25kW en 100kW. Stel dat de vraag naar perslucht zo groot is dat de drie compressoren met het minste vermogen de gevraagde hoeveelheid niet kunnen leveren. Een drukgestuurd systeem schakelt op dat moment alle vier de compressoren in het park in. Dit terwijl de 100kW compressor in zijn eentje ook in staat is om het gevraagde vermogen te leveren. De door ons ontwikkelde PEC Controller stuurt de compressoren aan op basis van flow. In deze situatie schakelt hij vanaf het begin alleen de 100kW compressor in. Voor u als bedrijfseigenaar is dit de meest energie-efficiënte keuze die voldoet aan de persluchtbehoefte.
Het grootste voordeel van debietregeling is de snelheid waarmee het systeem actie onderneemt, zodat het compressorpark rustig kan reageren. Dit resulteert in een optimaal energieverbruik.
We hebben ons eigen compressorbesturingssysteem uitgevonden: de PEC Controller. Onze PEC Controller is een gepatenteerde regelmodule die de prestaties van de compressor optimaliseert door een of meer units aan te sturen op basis van real-time vraag. Hierdoor kent de PEC Controller de status van de compressor en kan hij deze gericht aansturen.
- Werkt met compressoren met variabele snelheid, schroefcompressoren en olievrije compressoren.
- Past de uitvoer aan op basis van debiet in plaats van alleen druk.
- Centrale bediening via touchscreen of Presscon Studio (TCP/IP).
- Ondersteunt externe locaties met CAN-bus of UDP-communicatie.
- Controleert bedrijfsuren, stroomverbruik en vermijdt resonantiefrequenties.
De PEC Controller kan voor vrijwel elk type compressor worden gebruikt. Zowel voor frequentiegeregelde compressoren die met een vast vermogen in- en uitschakelen, als voor variabele frequentiegeregelde types. Het is ook mogelijk om compressoren met meerdere toerentalstappen aan te sturen.
Voordelen van de PEC Controller
- Energiebesparing door slimme debietregeling
- Controleert compressoren centraal
- Compatibel met veel compressormerken
- Voorkomt onnodig stroomverbruik
- Real-time bewaking via touchscreen of Presscon Studio
Geïnteresseerd in het verlagen van energiekosten? Neem contact op voor een gratis adviesgesprek.
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ONZE STIKSTOFGENERATOREN
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