With the development of industrial automation control technology, the demand for compressed air in industrial production is also increasing, and as the production equipment of compressed air - air compressor, it will consume a lot of electric energy during its operation. The power consumption of industrial air compressors accounts for about 6% of the total power consumption in the country, and its energy consumption accounts for about 10%-30% of the total energy consumption in most factories, and some enterprises even reach more than 50%.
1. Screw air compressor (energy-saving screw air compressor) replaces the piston machine
Although the industry has entered the era of screw machines for nearly two decades, at present, domestic air compressors use more piston machines. Compared with traditional piston compressors, screw air compressors have the advantages of simple structure, small size, higher reliability, stability, and simple maintenance.
2. Leakage control of air compressor pipeline
The average leakage of compressed air in factories is as high as 20-30%, so the primary task of energy saving is to control leakage. All pneumatic tools, hoses, joints, valves, a small hole of 1 square millimeter, under the pressure of 7bar, will lose almost 4,000 yuan a year. It is urgent to check the leakage of the air compressor pipeline and optimize the design of the pipeline.
3. Pressure drop management
Pressure gauges are installed at each section of the pipeline. Generally, when the air compressor is exported to the point of use in the factory, the pressure drop cannot exceed 1 bar, and more strictly, it cannot exceed 10%, that is, 0.7 bar. The pressure drop of the cold-drying filter section is generally 0.2 bar, check the pressure drop of each section in detail, and repair it in time if there is any problem. (Each kilogram of pressure increases the energy consumption by 7%-10%)
4. Assess the pressure demand of gas equipment
In the case of ensuring production, the exhaust pressure of the air compressor should be lowered as much as possible. The cylinders of many gas-consuming equipment only need 3~4bar, and a few manipulators only need more than 6bar. (For every 1bar lower pressure, about 7~10% energy saving)
5. Use high-efficiency compressors
For variable working conditions, the use of high-efficiency permanent magnet variable frequency screw air compressors or permanent magnet variable frequency two-stage air compressors is beneficial to energy saving. At present, the leading high-efficiency permanent magnet frequency conversion screw air compressor in China, its permanent magnet motor can save energy by more than 10% compared with ordinary motors; it has the advantages of constant pressure without causing waste of pressure difference; The single-stage permanent magnet variable frequency air compressor saves more than 30% energy than the general air compressor, and the permanent magnet variable frequency two-stage air compressor saves more energy.
6. Centralized control
The centralized linkage control of air compressors can avoid the stepwise exhaust pressure rise caused by the parameter setting of multiple air compressors, resulting in waste of output air energy.
7. Reduce the intake air temperature of the air compressor
Because the internal temperature of the general air compressor station is higher than the outdoor temperature, outdoor gas extraction can be considered. Do a good job of maintaining and cleaning the equipment, increasing the heat dissipation effect of the air compressor, maintaining oil quality, etc., all of which can reduce energy consumption.
8.Air compressor waste heat recovery
Air compressor waste heat recovery generally uses efficient waste heat utilization equipment to heat cold water by absorbing the waste heat of the air compressor without additional energy consumption. It mainly solves the problems of employees' life and industrial hot water, and saves a lot of energy for the enterprise, thus greatly saving the output cost of the enterprise.
Post time: May-19-2023
