Compressed Air in Cement Industry

Compressed Air in the Cement Industry

In cement manufacturing units, compressed air plays a pivotal role, powering various pneumatic machines and applications essential for efficient operations. Here’s a closer look at the key applications of compressed air in this industry:

Key Applications of Compressed Air

Ash Handling System: Compressed air is utilized to transport and manage ash, ensuring efficient disposal and maintaining cleanliness in the production area.
Tool Powering: Pneumatic tools powered by compressed air are used for various tasks, enhancing productivity and reducing manual labor.
Pneumatic Control and Actuators: These systems control processes and machinery, providing precise movements and operations within the plant.
Cleaning: Compressed air is effective for cleaning machinery and equipment, removing dust and debris that can affect performance.
Stamping: Air-powered stamping machines ensure accurate and efficient production of cement components.
Conveying: Compressed air systems facilitate the movement of materials throughout the plant, improving workflow and efficiency.

Maintaining Compressed Air Quality

To ensure optimal performance, it’s crucial to remove contaminants from the compressed air. Common issues include:

Water: Moisture can lead to corrosion and affect equipment longevity.
Dust Particles: Dust can clog systems, reducing efficiency and performance.
Oil Particles: Introduced by lubricated air compressors, oil can hinder processes and compromise product quality.
Solid Contaminants: These can damage equipment and lead to production issues.

Solution

Implementing effective air filtration and drying solutions can help remove water, dust, oil, and solid contaminants from compressed air. This not only enhances the efficiency of pneumatic systems but also prolongs the lifespan of equipment and ensures consistent product quality.

Piping Material Features Comparison
Piping Features	Stainless Steel(Type 304L)	Mild Steel	Blue anodized Aluminum Alloy
Weight (Dia 6inch, Length 6m)	127.2	169.6	29.142
Corrosion Resistant	Yes	No	Yes(100%)
Pressure drop (Dia 2 inch Length= 20m,Airflow=3 cubic metres/Minute, Pressure=10 bar)	0.25	0.4 Bar	0.1
Energy Efficiency	High	Low-moderate	High( Potential Cost savings of 34%)
Mechanical Strength	Very Strong	Very Strong	Strong
High-Temperature Rating	Yes	Yes	Yes
Installation Ease	Less Difficult	Difficult	Easy(High Flexibility and Modularity)
Installation Time	Approx 6 feet length per hour	Approx 6 feet length per hour	Approx 45 feet Length per hour
Work Hours/Manpower Required for a 2″ pipe and a 3000 feet piping	Approx 600 man-hours/8 men for 2 weeks	Approx 600 man-hours/8 men for 2 weeks	Approx 100 man-hours /8 men for less than 2 days
Annual Cost(Installation, Commissioning, and operation)	Approx 3000 dollars	Approx 7820 dollars	Approx 1300 dollars
Installation Cost Material%/Labor%	30% / 70%	25% / 75%	80% / 20%
Surface roughness	0.03	0.05	0.001
Special Tools Required (welder, threader, groove cutter)	Yes	Yes	No
Air Quality	High(Should the application require it, these pipe systems can help meet the requirements of ISO 8573-1: 2010 air quality standards.	Low( Not according to !SO 8573-2010 air quality standards)	High(Should the application require it, these pipe systems can help meet the requirements of ISO 8573-1: 2010 air quality standards.
Cost per meter	Almost 2 less than Aluminum	3 Times less than Aluminum	163.64 Dollars(Parker Transair)
Life Span( Will vary according to environmental factors, Pipe design, and Pipe grade.	30 years	40 years	20 years
Initial Cost of installations	Material : 30% Labor:70%	Material : 25% Labor:75%	Material : 80% Labor:20%
Maintenance	Difficult(Accumulation of rust under pipes and fittings which travels to machinery, may require preventive maintenance every week)	Difficult (Accumulation of rust under pipes and fittings which travels to machinery may require preventive maintenance every 3-4 days)	Easy (No accumulation of rust, may require preventive maintenance every 4 Weeks)