As one of the power sources of manufacturing enterprises, compressed air needs a continuous operation to ensure the stability of air supply pressure. This is the basic condition for the production and operation of enterprises, and the air compressor unit as the main manufacturing equipment is the core equipment to undertake this task. , Continuous and reliable operation is continuously required to ensure trouble-free and stable operation. Since it is an operating device, it needs a power supply to operate, and the high power consumption is the core of cost increase.
At the same time, in the process of continuous gas supply, whether there is leakage or ineffective use of the entire gas supply pipeline network system inside the enterprise the produced compressed air leaks in vain, which is another core of cost increase. To effectively reduce the use cost of the air compressor unit, we explain the following points.
1. In the technical transformation of equipment, it is necessary to pay attention to high-efficiency units, such as replacing piston compressors with screw air compressors. This is the development trend of equipment. Although the industry has entered the era of screw machines for nearly two decades, many domestic users are still using piston machines. Compared with traditional piston compressors, screw air compressors have the advantages of simple structure, small size, higher reliability, stability, and simple maintenance. The market share of screw air compressors is increasing year by year. Especially in recent years, energy-saving screw compressors have emerged continuously. Various companies are scrambling to launch products that are higher than the national energy efficiency level standards. It is hoped that every equipment renovation should pay attention to this issue.
2. Leakage control of the entire pipe network system during the use of compressed air. The average leakage of compressed air in the factory is as high as 20-30%, so the primary task of energy saving is to control leakage. All pneumatic tools, hoses, joints, valves, and a small hole of 1 square millimeter, under the pressure of 7 bar, 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. The ineffective use of leaked compressed air is a kind of power energy produced through energy consumption, electricity, and water, and it is a pity to let it leak in vain. I hope that enterprise managers will pay great attention to it.
3. Every time the compressed air passes through a piece of equipment, there will be a loss of compressed air, and the pressure of the air source will decrease. It is necessary to control the pressure drop, that is, to set up pressure gauges 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-dry filter section is generally 0.2 bar, check the pressure drop of each section in detail, and timely maintain if there is any problem. (Each kilogram of pressure increases the energy consumption by 7%-10%).
When selecting compressed air equipment and evaluating the pressure demand of air-consuming equipment, it is necessary to comprehensively consider the size of the air supply pressure and air supply volume, and the air supply pressure and total power of the equipment should not be increased blindly. In the case of ensuring production, the exhaust pressure of the air compressor should be lowered as much as possible. The cylinders of much gas-consuming equipment only need 3 to 4 bars, and a few manipulators only need more than 6 bars. (When the pressure is lowered by 1 bar, the energy saving is about 7-10%). For enterprise gas equipment, it is enough to ensure production and use according to the gas consumption and pressure of the equipment.
4. The selection of equipment needs to use high-efficiency compressors. According to the gas consumption situation of the enterprise, it is necessary to consider the peak and valley periods of gas consumption. Variable working conditions can be used, and high-efficiency permanent magnet variable frequency screw air compressors are used, which is beneficial energy saving.
At present, the leading high-efficiency permanent magnet variable frequency screw air compressor in China, its permanent magnet motor can save energy by more than 10% compared with ordinary motors and has constant pressure air, which will not cause waste of pressure difference. Advantage. More than 30% energy saving than ordinary air compressors. Frequency conversion production gas is especially suitable for modern production and manufacturing. Units with large gas consumption can also use centrifugal units. High efficiency and large flow can alleviate the problem of insufficient peak gas consumption.
5. Centralized control of multiple devices in the era of Internet big data is a good way to improve the management methods of modern enterprises. The centralized linkage control of multiple air compressors can avoid the stepwise exhaust pressure increase caused by the parameter setting of multiple air compressors, resulting in a waste of output air energy. The joint control of multiple air compressor units, the joint control of post-processing equipment and facilities, the flow monitoring of the air supply system, the monitoring of the air supply pressure, and the monitoring of the air supply temperature can effectively avoid various problems in the operation of the equipment and improve the reliability of the equipment operation.
6. Reduce the intake air temperature of the air compressor. The environment where the air compressor is located is generally more suitable to be placed indoors. Generally, the internal temperature of the air compressor station is higher than that of the outdoor, so 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, the exchange effect of heat exchangers such as water cooling and air cooling, and maintaining oil quality, etc., all of which can reduce energy consumption. According to the operating principle of the air compressor, the air compressor sucks in natural air, and after multi-stage treatment, multi-stage compression finally forms high-pressure clean air to supply other equipment. During the whole process, the natural air will be continuously compressed and absorb most of the heat energy converted from electric energy, and the temperature of the compressed air will rise accordingly. The continuous high temperature is not good for the normal operation of the equipment, so it is necessary to continuously cool down the equipment, and at the same time The re-inhaled natural air reduces the intake temperature and increases the intake air volume in an ideal state.
7. Waste heat recovery during compression. Air compressor waste heat recovery generally uses efficient waste heat recovery 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.
Dongguan Microvacuum Technology Co., Ltd. is a professional manufacturer of medical oil-free piston vacuum pumps and air compressors. With more than 15 years of product development and manufacturing experience, it has the latest complete sets of production equipment, as well as advanced testing equipment.
