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Necessity of energy saving transformation

             As an indispensable equipment of production enterprises, the air compressor is often the one that consumes a large amount of electricity in industrial and mining enterprises, and often accounts for 50% of the total power consumption of the whole plant. Its high operating energy consumption cost increases the operating cost of the enterprise invisibly; What is more serious is that the selection of air compressor system is old, the indicators deviate from the reality (too large or too small), the wear of the main engine, the parallel gas supply of multiple low-power equipment, the unreasonable pipeline layout, and the multi-point leakage can all cause huge energy waste.       

       Therefore, designing / upgrading a set of safe, reliable, energy-saving and stable pressure air compression system has become an urgent demand of enterprises.       

       The energy-saving transformation of the air compressor can achieve the purpose of saving energy, reducing energy consumption and reducing pollutant emission, and effectively reduce the production cost of the enterprise and create more profits for the enterprise.

Transformation mode

1. Screw air compressor replaces piston air compressor

Compared with the traditional piston compressor, the screw air compressor has the advantages of simple structure, small volume, high reliability, stability and simple maintenance. In the medium pressure field, the screw air compressor has higher compression efficiency

2. High performance compressor is adopted

According to different operating conditions, the use of high-performance centrifugal compressor, permanent magnet variable frequency screw air compressor or permanent magnet variable frequency two-stage air compressor is conducive to energy saving. At present, the domestic high-performance permanent magnet variable-frequency screw air compressor saves more than 30% energy than the general motor. The energy-saving advantages of the permanent magnet variable-frequency two-stage air compressor are more obvious. It has the advantages that the constant pressure air will not cause the waste of pressure difference, the amount of air used will be used, and the loading and unloading will not be required.

3. Air compressor pipeline treatment leakage

Generally speaking, the average leakage of compressed air in the factory is as high as 20-30%, so the important work of energy saving is to control the leakage.

Leakage points include: all pneumatic tools, hoses, connectors, valves, and a small hole of 1 mm2. Under the pressure of 7 bar, the annual loss is almost 4000 yuan.

The leakage in the plant usually accounts for 10% ~ 30% of the gas supply, while the poorly managed plant may even be as high as 50%

Power loss due to air leakage

4. Pressure drop treatment

Unreasonable pipeline planning, corrosion of the inner wall of the pipeline, and small selection of the gas pipe diameter will all cause pressure loss in the process of gas transmission. Each kilogram of pressure increase will increase energy consumption by 7% - 10%.

5. Pressure demand of gas consuming equipment

Under the condition of ensuring production, the exhaust pressure of the air compressor shall be adjusted as low as possible, or the model with matching pressure shall be selected. Energy saving is about 7-10% when the pressure is 1 bar lower.

6. Centralized control

Centralized linkage control of the air compressor can automatically start / stop the air compressor according to the actual gas consumption, and change the stop sequence of the machine to avoid energy waste.

7. Reduce the air inlet temperature of the air compressor

Since the internal temperature of the general air compressor station is higher than the outdoor temperature, outdoor gas gathering can be considered. Do a good job in equipment maintenance and cleaning, increase the heat dissipation effect of the air compressor and the exchange effect of water cooling, air cooling and other heat exchangers, and maintain the oil quality. All these can reduce energy consumption.