Pneumatics Fundamentals Training for Cement Plant Staff

Manufacturing Workforce Training
HGRS MASTER - MAINTENANCE
Training Module: Pneumatics Theory and Applications

Presentation: 01 Fundamentals
Version: 1.0
Last Update: 18-03-03
Objective
Pneumatics Theory and Application is intended to

be a comprehensive training material for all
technical staff within Holcim Group companies
This presentation covers the basic fundamentals of
pneumatic theory.
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Holcim Group Support Pneumatics Theory and Application 01 Fundamentals.ppt
Pneumatic Fundamentals
History of Compressed Air:
 Compressed air is one of the oldest forms of energy
known to man and has been applied to enhance our
physical capabilities for thousands of years.
 The first man to whom we know with certainty to have
engaged himself with pneumatics was the Greek
KTESIBIOS. More than 2000 years ago he built a
compressed air impulse catapult.
 The term “pneumatics” (the study of air movement and
air phenomena) was derived from the Greek word
“pneuma” which which means breath or wind.
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 Although the fundamentals of pneumatics rank amongst
the earliest perceptions of mankind, it was not until the
last century that the behavior and the fundamentals
were researched systematically.
 The true worldwide introduction of pneumatics in
industry came with the need for automation.
 In spite of initial rejection, (the main reason was due to
ignorance and lack of education), the fields of
application continue to increase.
 Today, it is impossible to imagine modern factories
being without compressed air. Compressed air devices
are installed in a very wide range of industries.
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 For the cement industry, compressed air or pneumatics
is applied in many applications.
 Some examples are:
 To transport materials (e.g. cement to silos)
 To control gates and valves (e.g. dosing gate)
 To clean off build (e.g. jet pulse dust collector)
 To handle components (e.g. cement bagging operation)
 To spray material (e.g. open gear spray system)
 etc.
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Advantages of Using Compressed Air
1. The amount of air is available practically everywhere
and in unlimited quantities.
2. Air can be easily transported in pipelines over long
distances and it is unnecessary to return the
compressed air to its source.
3. A compressor need not be in continuous operation.
Compressed air can be stored in and removed from a
reservoir. In addition, transportation of the reservoir is
possible (cylinder).
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4. Compressed air is insensitive to temperature
fluctuations. This ensures reliable operation, even
under extreme conditions of temperature
5. Compressed air offers no risk of explosion or fire,
hence no expensive explosive-protection equipment
against explosion is required.
6. Compressed air is clean. If any air escapes through
leaking pipes, it does not present an environmental or
housekeeping issue.
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7. The operating components are simple and
inexpensive.
8. Compressed air is a very fast working medium. This
enables high working speeds to be attained.
(Pneumatics cylinders have a working speed of 1-2
m/sec).
9. With compressed air components, speeds and forces
are infinitely variable.
10. Pneumatic tools and operating components can be
loaded to the point of stopping and they are overload
safe.
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Disadvantages of Using Compressed Air
1. Compressed air needs good preparation. Dirt and
humidity must not be present. (Wear of pneumatic
components.)
2. It is not possible to achieve uniform and constant
piston speeds with compressed air.
3. Compressed air is economical only up to a certain
force requirement. Under the normally prevailing
working pressure of 700 kPa (7 bar/101.5 psi) and
dependent on the travel and speed, the limit is
between 20000 and 30000 N (2000-3000 kp).
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Disadvantages of Using Compressed Air
4. The exhaust air is loud. This problem has now been
largely solved due to the development of sound
absorption material.
5. The production of compressed air has a relatively high
cost due to electrical energy consumption.
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Characteristics of compressed air:
 Air is the medium used in pneumatics.
 It is necessary and important to understand air’s
composition, physical properties, and characteristics to
effectively apply pneumatics in the cement industry.
 One characteristic air has as an advantage over other
mediums used in automation (oil, water, etc.) is that it
can forcibly expand in a relatively short length of time
readily and economically.
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What is Air?
 Air is a mixture of gases.
 The earth’s atmosphere contains air
which is necessary for life on our
planet. The surface of the globe is
entirely covered by this mantle of air.
 The gas composition of atmospheric
air is:
 Nitrogen ~ 78%
 Oxygen ~ 21%
 Carbon Dioxide, Hydrogen, Helium,
Argon, Xenon, Neon, Krypton, etc ~
1%
 The following substances are also
found in atmospheric air:
 Dust, soot, sand, moisture, etc.
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Does Air Exist?
 Although pure air is:
 Tasteless
 Odorless
 Colorless
 The presence of air can be proved:
Through our breathing By flying kites By a whirling pinwheel
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Does Air have Weight?
 This fact can be proven in the following scenario:
 By removing air from a container with a vacuum pump
 And comparing the container without air to one with air.
 Also, the weight of a specific volume of air varies with

temperature.
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Atmospheric Pressure
 Since air has weight, its influence should be felt.
 Atmospheric pressure is a result of the weight of the air.
 The atmospheric pressure is not felt because it acts in
all directions with the same intensity.
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 Atmospheric pressure
may be measured with
the aid of a Mercury
Barometer.
 For the normal standard
conditions of air at 0°C
and altitude at sea level,
 Patmosphere is equal to the
following:
1 atmosphere = 760 mmHg = 14.7 psi = 101.3 kPa = 1.013 bar

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 The actual atmospheric pressure does not have a
constant value. It varies depending on weather
conditions and altitude above sea level.
P4 > P3 > P2 > P1

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Pgauge = Pabsolute - Patmosphere
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Air Moisture
 A sample is saturated if it
contains the maximum
possible amount of water
vapor.
 The actual amount of water
vapor present in the sample
is called absolute humidity.
 The ratio between absolute
humidity and humidity of a
saturated sample is known
as relative humidity.
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 Air is compressible.
 In common with all gases, air has no particular shape.
Its shape changes with the slightest resistance. i.e. it
assumes the shape of its surrounding.
 The applicable relationship that describes the physical
relationships of air is the Ideal Gas Law.
P: Pressure
PV = nRT V:
n:
Volume
Number of Moles
R: Universal Gas Constant
T: Temperature
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Physical Transformation of Air
 According to Boyle’s Law, at constant temperature:
 P0V0 = P1V1 = P2V2 = constant
Air Compression
Pressure P2 < P1
Pressure P0 Pressure P1 > P0
Volume V2 > V1
Volume V0 Volume V1 < V0
P1 V1 = P2 V2
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 According to Charles’s Law, at constant pressure:
 V3 / T3 = V4 / T4 = constant
Air Expansion
Temperature T3 Temperature T4 > T3

Volume V3 Volume V4 > V3
V3 / T3 = V4 / T4
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 Compression in a real life situation.
Pressure increases
Volume decreases
Temperature increases
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Air Compression Processes
 Adiabatic Process: no
energy in the form of heat
is exchanged with the
environment.
Consequently the
temperature of the air
rises.
 Isothermal Process: the
temperature of the air is
kept constant through a
perfect heat exchange
system.
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Air Compression Processes
 In reality, it is impossible to have either a completely
adiabatic process or a completely isothermal process.
 Therefore most systems in industry have combinations
of both, which is referred to as a Polytropic Process.
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Air Compression
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Air Compression
28
Air Compression
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Air Compression
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Air Compression
Adiabatic
Isothermal
Polytropic
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Energy Balance
 The energy balance for an actual compression system
is:
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Energy Balance
 Since the percentage of
energy transformed into heat
is high, it is necessary to
have a cooling system to
keep the temperature (T2)
low.
 The ratio between the output
and the input temperatures
(T2/T1) is given for each
compression stage.
 Normally one uses more than
one stage of compression
with air inter-cooling.
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Pneumatics Fundamentals Training for Cement Plant Staff

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Manufacturing Workforce Training

HGRS MASTER - MAINTENANCE

Training Module: Pneumatics Theory and Applications

Pneumatics Theory and Application is intended to

Through our breathing By flying kites By a whirling pinwheel

 Also, the weight of a specific volume of air varies with

1 atmosphere = 760 mmHg = 14.7 psi = 101.3 kPa = 1.013 bar

P4 > P3 > P2 > P1

 P0V0 = P1V1 = P2V2 = constant

Temperature T3 Temperature T4 > T3

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