Central compressed air generation facility

Abstract

This invention is a method for the production and distribution of compressed air in organized industrial zones (OIZs), specifically involving the centralized production of compressed air using energy-efficient turbo compressors and its transmission to industrial facilities via high-pressure conveying lines. The method aims to produce compressed air more efficiently and minimize energy losses during transport, thanks to the low energy consumption and multi-stage compression mechanism of turbo compressors. This method also ensures fair and accurate billing based on the measurement of compressed air consumption supplied to industrial facilities. Each industrial facility is equipped with high-accuracy meters to precisely measure the amount of compressed air consumed. Data from these meters is collected and processed in real time via a central control system. Billing is then based solely on the amount of air consumed. The system aims to reduce operating costs through energy efficiency and low maintenance costs, as well as to ensure environmental sustainability by reducing carbon emissions. The fact that turbo compressors offer lower energy consumption and maintenance requirements compared to screw compressors increases the overall efficiency of this method and provides economic advantages.

Description

[0001] DESCRIPTION

[0002] CENTRAL COMPRESSED AIR GENERATION FACILITY

[0003] Technicalfield

[0004] This invention is a method for the production and distribution of compressed air in organized industrial zones (OIZs), specifically involving the centralized production of compressed air using energy-efficient turbo compressors and its transmission to industrial facilities via high-pressure conveying lines. The method aims to produce compressed air more efficiently and minimize energy losses during transport, thanks to the low energy consumption and multi-stage compression mechanism of turbo compressors.

[0005] This method also ensures fair and accurate billing based on the measurement of compressed air consumption supplied to industrial facilities. Each industrial facility is equipped with high-accuracy meters to precisely measure the amount of compressed air consumed. Data from these meters is collected and processed in real time via a central control system. Billing is then based solely on the amount of air consumed.

[0006] The system aims to reduce operating costs through energy efficiency and low maintenance costs, as well as to ensure environmental sustainability by reducing carbon emissions. The fact that turbo compressors offer lower energy consumption and maintenance requirements compared to screw compressors increases the overall efficiency of this method and provides economic advantages.

[0007] State of the art

[0008] In current technologies, compressed air production in industrial facilities is generally achieved using screw compressors. Screw compressors are widely preferred in the industrial sector and are known for their relatively low initialinvestment costs and ease of use. However, these devices have a very high energy consumption. Screw compressors consume approximately 6.5 kW of energy to produce 1 m3 / min of air, while turbo compressors consume only 5 kW of energy to produce the same amount of air. This shows that screw compressors have a significant disadvantage in terms of energy efficiency.

[0009] Screw compressors also have drawbacks in terms of maintenance and operating costs. These devices require frequent maintenance and have a high need for spare parts. This increases operating costs in industrial facilities and also leads to production stoppages, causing time loss.

[0010] Turbo compressors, however, are a less commonly used alternative in current technology. The main reasons for this include the higher initial investment costs of turbo compressors compared to screw compressors and the lack of sufficient awareness among industrial enterprises regarding energy efficiency. However, turbo compressors are much more advantageous than screw compressors due to their energy efficiency, low maintenance requirements, and longer lifespan. The multi-stage compression mechanism of turbo compressors reduces energy losses while providing a continuous and stable compressed air flow. Furthermore, the fact that turbo compressors produce oil-free air improves compressed air quality, positively impacting the efficiency of industrial processes.

[0011] In conclusion, screw compressors, commonly used in industrial facilities for compressed air production in current technologies, have significant disadvantages such as high energy consumption, maintenance costs, and air waste. In contrast, despite the energy efficiency and usability advantages of turbo compressors, their limited application area can be considered a significant shortcoming of current technology. Our invention addresses these deficiencies in existing technologies by systematically integrating the energy efficiency advantages of turbo compressors into organized industrial zones. By centrally positioning the turbo compressors, high-pressure air production is achieved with less energy consumption, and theproduced air is conveyed to factories via dedicated conveying lines. This system eliminates the disadvantages stemming from the high energy consumption of screw compressors and increases energy savings by 25%.

[0012] Furthermore, the consumption of compressed air reaching factories is measured with precise meters, and billing is based only on the amount used. This method prevents energy waste while also reducing costs for businesses. Thanks to the system's low maintenance requirements and long lifespan, maintenance costs are reduced by 40% (in addition to 25% energy savings, savings from maintenance and prevention of production losses result in a 40% saving), production downtime is minimized, and efficiency is increased in industrial facilities.

[0013] Furthermore, our invention offers significant environmental benefits. The reduction in energy consumption lowers carbon emissions, thereby reducing environmental impacts. This system, which provides revolving fund contributions to Organized Industrial Zone managements, offers a structure that aligns with both economic and environmental sustainability goals.Detailed description of the invention

[0014] This invention is based on the production of compressed air using turbo compressors centrally located within organized industrial zones (OIZs). Turbo compressors operate with high efficiency and lower energy consumption (5 kW per 1 m3 / min) compared to screw compressors. Thanks to their multi-stage compression mechanism, these efficient compressors minimize pressure losses and provide a more stable, continuous airflow.

[0015] There are 360 organized industrial zones in Tiirkiye. In addition to these zones, there are also many businesses in free zones and in various other sectors such as the food and textile industries. This diversity increases the need for innovative solutions to improve competition and efficiency in the industry. The system developed in this context is based on the principle of utilizing all of the compressed air produced. The air is conveyed to industrial facilities via high-pressure conveying lines specifically designed for this purpose. These conveying lines are isolated and optimized to minimize energy losses. Each facility is equipped with a high-precision metering system to measure the compressed air it receives. The meters measure the airflow, determining the total air consumption of each factory. This data is transmitted wirelessly to a central control system, allowing for real-time monitoring of the factories' air consumption.

[0016] Billing is done using data from meters, and each facility pays according to the amount of air it uses. This system prevents unnecessary energy consumption and increases the energy efficiency of businesses. Energy consumption is significantly reduced thanks to the use of turbo compressors. For example, in an industrial area with an annual air consumption of 50,000 m3 / min, energy savings of 450,000,000 kWh can be achieved with turbo compressors. (This saving is estimated for an average of 500 production facilities .)The system also has low maintenance costs because turbo compressors require less maintenance than screw compressors, minimizing downtime. This reduces production losses and results in overall savings of up to 40%.

[0017] This system also provides environmental benefits. Low energy consumption reduces carbon emissions, thus offering an eco-friendly approach. Furthermore, it provides economic contributions by generating revolving fund income for Organized Industrial Zone (OSB) administrations.

[0018] Technical Details and Methodology of the Invention

[0019] This invention presents a system that includes advanced technical infrastructure for the production of compressed air using turbo compressors centrally located in organized industrial zones (OIZs), its distribution via designed conveying lines, and its consumption measurement. The system is implemented through the following physical and technological components:

[0020] Basic Steps of the Method

[0021] 1. Compressed Air Generation Unit (Turbo Compressor System)

[0022] Compressed air is produced by turbo compressors located in a central location within the Organized Industrial Zone (OSB). These turbo compressors are:

[0023] Air or gas enters: The gas entering the turbine wheel is accelerated.

[0024] Kinetic energy is generated: The rotation of the wheel increases the kinetic energy of the gas.

[0025] Pressure is increased: As the gas is slowed down in the diffuser, its kinetic energy is converted into pressure.

[0026] A constant and high flow rate is ensured: A continuous supply of high-volume and high-pressure air is obtained.Turbo compressors are particularly preferred for industrial processes requiring high capacity and continuous flow.

[0027] Working Principle of Turbo Compressor and Cooling Tower

[0028] The high amount of heat generated by turbochargers during operation can affect performance and equipment lifespan. Therefore, cooling towers are a critical support element for turbochargers.

[0029] Cooling Tower Operating Principle:

[0030] Hot water leaves the compressor and is pumped to the cooling tower.

[0031] As the water flows down the tower from top to bottom, it is cooled by fans.

[0032] Temperature decreases through evaporation; some of the hot water evaporates, lowering the temperature of the remaining water.

[0033] The cooled water returns to the turbocharger.

[0034] Why is it necessary?

[0035] Thermal management: This is essential for ensuring the proper functioning of turbochargers and preventing overheating.

[0036] Efficiency: Lower temperatures increase the energy efficiency of the compressor. Long lifespan: Extends the lifespan of system components.

[0037] Advantages of Turbo Compressors Over Screw Compressors

[0038] Higher Capacities:

[0039] Turbo compressors can operate at much higher flow rates compared to screw compressors.

[0040] In large industrial facilities, a single turbo compressor can do the work of multiple screw compressors.

[0041] Lower Operating Costs:Screw compressors have more moving parts, therefore requiring higher maintenance. Turbo compressors have fewer moving parts, which reduces maintenance costs.

[0042] Improved Energy Efficiency:

[0043] It provides energy efficiency in applications requiring high pressure and continuous flow.

[0044] High-Speed Operation:

[0045] Turbo compressors operate at higher speeds, providing greater energy savings and high efficiency with a smaller volume.

[0046] Less Wear and Tear:

[0047] Because it contains fewer mechanical parts than screw compressors, it has a longer lifespan.

[0048] In conclusion, turbo compressors offer a superior option for high-capacity industrial applications. However, screw compressors are generally more suitable for smaller-scale or variable-flow applications.

[0049] 2. Compressed Air Distribution Line

[0050] The air produced is conveyed through transmission lines designed for industrial facilities and having the following characteristics:

[0051] High-Pressure Steel Pipes: Steel pipes that minimize pressure losses and are resistant to external influences are used. These pipes are reinforced with smooth inner coatings to reduce friction in airflow.Insulation Layers: To prevent energy losses, the pipes are covered with thermal insulation materials. This insulation prevents ambient temperature changes from affecting airflow.

[0052] Pressure Regulators: Pressure regulators, placed at specific points along the line, increase the overall efficiency of the system by maintaining a constant air pressure.

[0053] 3. Consumption Measurement System (Meter and Data Collection Infrastructure)

[0054] The compressed air supplied to industrial facilities is measured by high-precision meters installed at the entrance of each facility:

[0055] Digital Data Transmission Modules: Data from the meters is sent to the central control system via wireless communication modules. These modules transmit consumption data in real time and store it on the central server.

[0056] Data Processing Software: Consumption data is analyzed through centralized software, and billing is automatically generated for each facility.

[0057] 4. Billing and Centralized Control System

[0058] The billing process is carried out through an automated software infrastructure integrated into the central control system.

[0059] Consumption Data Analysis: Centralized software collects meter data from each factory and calculates total consumption. This software matches energy consumption with the amount of air used, ensuring that factories only pay for the air they consume.

[0060] User Interface: Through this software, the Organized Industrial Zone (OSB) management can view the consumption history of the facilities and generate energy efficiency reports.

[0061] 5. Energy Efficiency and Environmental ContributionsLow Energy Consumption: The use of turbo compressors reduces energy consumption by 25% compared to screw compressors. This results in an energy saving of 450,000,000 kWh in an Organized Industrial Zone with an annual air consumption of 50,000 m3 / min.

[0062] Carbon Footprint Reduction: Carbon emissions are significantly reduced through energy efficiency.

[0063] 6. Ease of Maintenance and Operation

[0064] Low Maintenance Requirements: The design of turbochargers reduces maintenance intervals due to having fewer moving parts. In addition, the integrated remote monitoring system enables early detection of malfunctions.

[0065] Uninterrupted Operation: The system is equipped with redundant compressors and conveyor lines, preventing production interruptions.

[0066] This method, thanks to the harmonious operation of the physical infrastructure and technological components used in compressed air production and distribution, both increases energy efficiency and offers significant economic and environmental benefits to businesses.

Claims

CLAIMS1) This is a method used for the production and distribution of compressed air in organized industrial zones (OIZs), and its characteristic feature is;Generating compressed air using turbo compressors at one or more central locations in the industrial zone,The hot water coming from the compressor is cooled in cooling towers by reducing its temperature through evaporation and then sent back to the compressor.Turbo compressors consume 5 kW of energy for every 1 m3 / min of compressed air produced, thus providing energy savings.The compressed air produced is conveyed to industrial facilities via isolated and optimized high-pressure conveying lines.Industrial facilities should be equipped with high-precision meters that measure air consumption in real time.The data obtained from the meters is collected through a central control system.The central control system involves analyzing the air consumption of each industrial facility using the collected data and billing accordingly2) This is a method that complies with Claim 1, and its characteristic feature is;Turbochargers provide a more stable and continuous airflow through their multi-stage compression mechanism.Compared to screw compressors, it consumes 25% less energy while producing the same amount of air, and this includes the process steps involved.3) This is a method that complies with Claim 1, and its characteristic feature is;The compressed air produced is conveyed to industrial facilities without loss via high-pressure conveying lines.The system involves installing meters in industrial facilities to continuously monitor each facility's air consumption and prevent waste.4) This is a method that complies with Claim 1, and its characteristic feature is;The collection of consumption data from meters installed in industrial facilities through a central control system.The central control system includes steps to ensure that each facility is billed only for the amount of air consumed by analyzing its air consumption.