Vacuum and overpressure system optimization
onsiderable opportunities exist for energy efficiency of vacuum systems. These possibilities can be realized through needs-adapted approaches to the systems as well as the use of energy-efficient components and control methods. Experience from studies in the field shows that in many cases a potential of 40 - 50% can be realized compared to conventional systems.
Overpressure systems are similar to the corresponding vacuum systems but operate with overpressure (typically 0.5 - 1.5 bar). In many cases, overpressure systems can substitute compressed air systems with, for example, blowing or atomizing nozzles. Experience from field studies shows that in many cases a potential of up to 80% can be realized compared to conventional compressed air systems with nozzles.
concept for optimizing vacuum and overpressure systems is developed based on the use of latest technology in components and control based on a demand-driven approach. The need-driven approach to system optimization and the methods for this, including necessary registrations, are used in an energy optimization tool for energy optimization of existing and design of new vacuum and overpressure systems developed in the project. In addition, the methods are documented in a guide based on a specific methodological approach illustrated with examples from existing vacuum and overpressure / compressed air systems at the participating companies.
A new, independent tool is developed for the needs optimization of vacuum and overpressure systems based on the latest knowledge of the operation of vacuum and overpressure pumps (in principle the same component), forms of regulation etc. The tool is in principle built up as the hydraulic tool, which was developed in ELFORSK project 349-016 "Optimization of hydraulic systems". That is, the tool will in principle consist of a process part with the possibility of selecting several processes with different flow and pressure needs as well as a pump and motor part where different types and sizes can be selected.
In connection with the above, a guide for the design of energy efficient vacuum and overpressure systems is developed since experience is that the interaction between the capacity of the pump and the regulation of the air pressure in relation to actual needs is essential in order to ensure optimal, energy efficient operation.
The main results of the project are:
- Optimization tool for vacuum and overpressure systems
- Design guide for vacuum and overpressure systems
- Draft a "small blue" for vacuum and overpressure systems
- Reporting incl. mapping potentials across sectors and technologies
Overall, the vacuum industry, their customers and the advisors are ensured new knowledge to realize very significant energy efficiency improvements, taking into account the actual needs for hydraulic operation.
In order to realize this great energy saving potential, it is necessary to have a well-suited optimization tool and a guide for energy-conscious design of vacuum and positive pressure systems, where the specific needs in the individual case are taken as a starting point and which are supported by the optimization tool.
In the project, a tool has been developed for need-based optimization of vacuum systems based on the latest knowledge about the operation of vacuum pumps, control methods, etc.
During the development of the tool, mathematical expressions for vacuum pumps have been drawn up on the basis of data from data sheets or performance curves. An advanced energy calculator part has been developed that can handle the various forms of regulation that are used in the before and after situation, and on the basis of this, the optimization options are calculated.
In the project, a guide has been developed for the energy-conscious design of vacuum and overpressure systems, which is supported by the above-mentioned optimization tool, where the starting point is how companies' needs for a reliable and energy-optimal vacuum and overpressure supply are met.
The design guide provides guidelines for choosing vacuum pumps, high-pressure blowers, motors, regulation, etc. In addition, it describes how existing vacuum and overpressure systems are examined with the aim of providing data for the design tool, so that it is possible to use the tool for estimating the energy savings through energy optimisation.
The project is financed by the ELFORSK program with project no. 352-059 and was carried out by the following project participants in the period 1 May 2020 to 31 December 2022.
- • Teknologisk Institut
- • Skjern Paper A/S
- • Berry Superfos A/S
- • Busch Vakuumteknik A/S
- • AURA A/S
Key figures
Category
Participants
| Partner | Subsidy | Auto financing |
|---|---|---|
| Busch Vakuumteknik A/S | ||
| Skjern Papirfabrik A/S | ||
| RPC Superfos A/S | ||
| AURA Rådgivning A/S |
