Exergy analysis of pressure reduction, back pressure and intermittent air supply configuration of utilization/expansion stage in compressed air systems

Despite their many advantages, industrial compressed air systems are characterized by high energy consump-tion and very low energy efficiency. This is primarily due to the oversizing of pneumatic actuators, leading to excessive compressed air consumption in the utilization stage. Various methods have been proposed in the literature to address this issue, which can be classified into three groups: supply pressure reduction, back pressure increase, and intermittent power supply. However, no exergy analysis compares these methods in the utilization stage of a pneumatic system was performed. In this study, we conducted an exergy analysis to compare the exergy consumption and exergy savings of different pneumatic system configurations: the classic configuration, supply pressure reduction, back pressure increase, and intermittent power supply. The paper shows the most key places in CAS in terms of exergy losses, which result mainly from dead volumes, outlet loss and oversizing of components such as directional control valve, distributed pneumatic line and actuator. Losses in those components can amount to over 80% of input exergy and can be reduced even 3-9 times. Exergy evaluation of oversizing configurations showed that the highest exergy savings were obtained for a back pressure configuration (77%) and intermittent air supply (75%). The exergy savings for the pressure reduction configurations amounted to almost 50%. The paper presents mathematical models for several individual pneumatic components, including the actuator, directional control valve, muffler, pneumatic line and pressure reducer. The demonstrated mathematical model and exergy analysis can play a instrumental role in evaluating the exergy efficiency and optimization of a pneumatic system.