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Training Course in Compressed Air Technology

Kaeser Kompressoren 2000

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Training Course in Compressed Air Technology

Kaeser Kompressoren 2000

http://www.kaeser.com

Topics

Basic principles of compressed air technology Control systems

Sizing a compressor installation The generation of compressed air

The compressed air system

Economic appraisal Planning a compressor installation The principles of heat recovery

The treatment of compressed air


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1. Training Course in Compressed Air Technology

What is compressed air?


Compressed air is ...
... compressed atmospheric air ... a mixture of gases ... compressible ... an energy carrier

grid system user transformer Power station

air main Air centre user air treatment

Proportional relationship between pressure, temperature and volume:

still valid:

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1. Training Course in Compressed Air Technology


Basic units m = Meter s = Second K = Kelvin kg A = Kilogram = Ampere

mol = Molar mass

Derived units

= Newton

Pa = Pascal
= Ohm

bar = Bar J C = Joule = Celsius

W = Watt Hz = Hertz

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1. Training Course in Compressed Air Technology

Physical laws
COMPRESSED AIR is atmospheric air under pressure. That means energy is stored in the air. When the compressed air expands again this energy is released as WORK. pressure (energy)

WORK

EXPANSION
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1. Training Course in Compressed Air Technology

Components of air
oxygen 21% other gasses 1%

nitrogen 78%
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1. Training Course in Compressed Air Technology

Atmospheric pressure...
...is generated by the weight of the atmosphere. It is dependent on the DENSITY of the air and the height:

The normal atmospheric pressure at sea level is 1.013 bar (760 mmHg (Torr))

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1. Training Course in Compressed Air Technology


Absolute pressure ...
... is the pressure measured from absolute zero. It is used for all theoretical approaches and is required in vacuum and blower techniques. pamb

Gauge pressure ...


... is the practical reference pressure and is based on atmospheric pressure.

atmospheric pressure

absolute pressure
(g) (g)

(g)

(g)
Pg

vacuum 100% vacuum

gauge pressure

0%
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1. Training Course in Compressed Air Technology

Definition of pressures
Equivalents Generally: Pressure (p) = Dimensions: 1 Pascal (Pa) = 1 Newton (N) 1 m (A) Force (F) Area (A)
105 Pa 1 MPa 1 hPa = = = 1 bar 10 bar 0,001 bar

Gauge pressure 1 bar = 14,5 psi(g) 1 bar 1 bar = = 10197 mmWC 750,062 Torr

A = 1 m2

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1. Training Course in Compressed Air Technology

Natural laws
Isotherms (constant temperature)
If the volume is reduced under constant temperature, the pressure increases.

p0 x V0 = p1 x V1 = constant

Heat dissipation
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1. Training Course in Compressed Air Technology

Isotherms (constant temperature)


p Heat dissipation p1
1

T0 = T1
0

p0 V1
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dV

V0

V
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1. Training Course in Compressed Air Technology

Natural laws
Isobars ( constant pressure )
If heat is applied under constant pressure, The air volume behaves directly proportional to its absolute temperature.

Application of heat

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1. Training Course in Compressed Air Technology

Isobars (constant pressure)


p Application of heat

p0 = p1
p0= p1 0 1 T1

T
0

V0
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dV

V1

V
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1. Training Course in Compressed Air Technology

Natural laws
Isochors (constant volume)
If heat is applied with constant volume, the pressure behaves directly proportional to the absolute temperature.

Application of heat

p p

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1. Training Course in Compressed Air Technology

Isochors (constant volume)


p

V0=V1
p1 1 T1

p0

0
V0=V1

T0 V
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Application of heat
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1. Training Course in Compressed Air Technology

Adiabatic or Isentropic
(no heat transfer)
Heat insulation
If the volume is reduced and heat cannot be dissipated, temperature increases with the pressure

p
p p

p1

p0 V1
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0
dV

T1 T0

V0

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1. Training Course in Compressed Air Technology

Theoretical performance requirement


(specific, for compression from 1 bar absolute)

n = 1.4
Pspec

kW m3/min

Isentropic

n = 1.3 n = 1.1 n = 1.0

Isothermal

p1 p0

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1. Training Course in Compressed Air Technology

Gas equation
Gas law relating to a closed system:

p0 x V0 T0
p V T R = = = =

p1 x V1 T1

= R = constant

pressure (bar (absolute)) volume (m3) temperature (K) special gas constants
J e.g. R = 28.96 barm = 289.6 kgK K for dry air

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1. Training Course in Compressed Air Technology

Definition of volumes
Temperature
Volume according to DIN 1343 (normal physical state) Volume according to DIN/ISO 2533 Volume related to atmosphere (normal state)

Pressure 1,01325 bar 1,01325 bar


atmospheric pressure working pressure

Relative humidity 0%

Density 1,294 kg/m 1,225 kg/m


variable

0C = 273,15K 15C = 288,15K


atmospheric temperature working temperature

0%
atmospheric humidity

Volume related to operating state

variable

variable

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1. Training Course in Compressed Air Technology

Volume
7 m atmospheric air volume

ambient air pressure 1 bar (a)

working pressure 7 bar (a) = 6 bar (g)

1 working m

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1. Training Course in Compressed Air Technology

Volume

Expansion:
Working pressure 7 bar (a) = 6 bar (g) Ambient air pressure p0, V0

Working pressure p1, V1

The volume of atmospheric air decreases at an inverse ratio to the respective absolute pressures (at constant temperature, without taking humidity into account)
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p
p
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1. Training Course in Compressed Air Technology

Conversion of normal volume to


volume according to DIN 1343

VN =
VN VI TN TI pN pI Hrel pD air = = = = = = = =

VI x TN x (pI - (Hrel x pD)) pN x TI

Normal volume to DIN 1343 Volume at inlet conditions Temperature to DIN 1343, TN = 273.15K Maximum temperature at the installation in K Air pressure to DIN 1343, pN = 1.01325 bar Lowest air pressure at the installation in bar Maximum relative humidity in the air at the installation Saturation pressure of the water vapour contained in the in bar, dependent on the temperature of the air

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1. Training Course in Compressed Air Technology

Extract from the table for the saturation pressure of water vapour at saturation
t pD
0,00260 0,00280 0,00310 0,00340 0,00370 0,00400 0,00440 0,00480 0,00520 0,00560 0,00610 0,00640 0,00710 0,00740 0,00810 0,00870 0,00940 0,01000 0,01070 0,01150

t
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

pD
0.0123 0.0131 0.0140 0.0150 0.0160 0.0170 0.0182 0.0184 0.0206 0.0220 0.0234 0.0245 0.0264 0.0281 0.0298 0.0317 0.0336 0.0356 0.0378 0.0400

t
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

pD
0.0424 0.0449 0.0473 0.0503 0.0532 0.0562 0.0594 0.0627 0.0662 0.0699 0.0738 0.0778 0.0820 0.0864 0.0910 0.0968 0.1009 0.1061 0.1116 0.1174 0.1234

Saturation pressure pD (bar) at air temperature t ( C)

-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9

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1. Training Course in Compressed Air Technology

Flow velocity in air lines

A1 v1
valid is:

A2 v2

V = A1 x v1 = A2 x v2
V v A
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A1 v2 = v1 A2

= = =

flow volume velocity pipe sectional area


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1. Training Course in Compressed Air Technology

Flow profile
pipe wall

border layer

flow velocity

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1. Training Course in Compressed Air Technology

Flow types
We differentiate between: laminar (even) and turbulent (swirling) flow

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1. Training Course in Compressed Air Technology

Compressed air in motion


Pressure loss is dependent on:
sectional area velocity pipe length internal surface area of the pipe
length (m) Pressure (bar)

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1. Training Course in Compressed Air Technology

Some graphical symbols


for pneumatic systems ( ISO 1219):
Double-acting cylinder Silencer Cooler

Compressor

Safety valve

Pressure measurement - pressure gauge

Temperature measurement - thermometer

Filter or strainer

for logical circuits:


AND function NOT function

OR function

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