Estudo de Caso de Redução de Perdas de Energia por Vazamentos Provocados por Excesso de Corrosão e Temperaturas Elevadas no Sistema de Ar Comprimido de uma Fábrica de Biscoitos em Serra Espírito Santo

  • Osiel S. Luiz Federal Institute of Espírito Santo - professional master's student in Control and Automation Engineering Campus Serra-ES
  • Flavio B. B. Silva Federal Institute of Espírito Santo - professional master's advisor in Control and Automation Engineering Campus Serra-ES
Keywords: Compressor, pneumatic, maintenance, energy efficiency


Faced with the growing increase in industrial activity, cost reduction becomes a preponderant factor, given the fierce competition in this sector. In this context, the reduction of energy costs appears as a strong ally in the search for more efficient means of production from an economic and environmental point of view. This study shows that it is possible to obtain excellent results by implementing methodologies to control losses caused by leakage and temperature. Although the main objective of the implementations is to increase productivity, reduce energy and operational costs, the reduction of energy losses also contributes significantly to the environment, allowing a better use of available resources. The study was carried out in a small biscuit factory, located in the municipality of Serra-ES, with the objective of presenting a technical, economic and environmental feasibility study to reduce energy losses in the compressed air system, considering which company uses large-scale pneumatic equipment, driven by air compressors. Maintenance reports pointed out that in the last three years, there have been consecutive increases in maintenance costs resulting from leaks, arising from the corrosion process, generating numerous unscheduled stops in production in the compressed air system. Based on this information, it was proposed to replace the pipe with a new one, so as not to stop production during the execution of the project. It was also proposed to use anti-corrosion protection to increase the useful life of the new pipeline. These measures proved to be quite effective, allowing a reduction of R$ 9,566.53 per year in electricity. An increase in efficiency was also sought after, by reducing the temperature of the air admitted by the compressor, since the excess energy consumed by the equipment, due to the high temperatures inside the engine room, in relation to the external environment generates an extra energy cost of BRL 3,148.98 per year.