Everyone is doing compressor energy saving transformation, you have to master these dozens of methods

Everyone is doing compressor energy saving transformation, you have to master these dozens of methods

Replacement of compressor air source with energy-saving compressor

　　In today's industrial field, screw compressors have become the largest type of compressors due to their sturdiness and ease of maintenance, and they have a wide range of uses. However, the energy efficiency of screw compressors is still hovering at a low level. Only about 20% of the power input to the screw compressor is converted into effective compressed air power, and the rest is converted into heat. If the efficiency of the screw compressor itself is improved and an energy-saving screw compressor is realized, huge benefits will be obtained.

　　 Alternatively, centrifugal compressors can be selected through selection and calculation, but this method has a relatively large investment, and it is not recommended unless the user company has the intention.

　　 Gas transmission pipeline and tip optimize energy saving

　　Once compressed air is generated, it needs to be transported to the use place through the air storage tank and pipeline. During the transportation process, the pipeline often has problems. These problems increase energy consumption and cause unnecessary waste. By optimizing energy-saving means for pipelines and terminal gas utilization links, substantial energy savings in the compressor system can be achieved. This chapter explains common pipeline problems and briefly introduces the solutions.

　　 1. Insufficient gas tank capacity

　　In the application field, the problem that often occurs is that the capacity of the gas storage tank is insufficient. Due to the small capacity, the energy storage function is poor, and the pressure fluctuation is large, causing the compressor to be repeatedly loaded and unloaded, resulting in a large amount of energy waste. By increasing the gas storage tank, the single unloading time exceeds a certain period of time, then the unloading power consumption of the compressor will be reduced, forming an energy-saving effect.

　　2. Right angle elbow

　　 The right-angle elbow at the pipe joint has a great destructive effect on energy efficiency. The reasons are:

　　A. The right-angle elbow forms a gas impact, and the local pressure increases, causing the compressor to continue to operate at a high pressure and easy to unload.

　　B. The right-angle elbow increases the flow resistance and forms an additional work point.

　　 For the right-angle elbow of the compressor output port, the pressure of 0.5bar can be used in severe cases. If a 6.5bar pressure system is used on site, the energy loss of the right-angle elbow accounts for more than 7%, and the degree of damage is evident. Reasonable optimization of pipeline connection points can significantly reduce energy loss, and this part of the loss is almost eliminated.

　　3. Poor pipeline direction

　　 After the compressed air is sent out from the unified gas storage tank, it is transported to the gas utilization link through various pipelines. The efficient transport forms include single-point daisy chain and multi-point ring. However, due to the saving of one-time investment and other reasons at the general user site, the direction of the air pipeline is often unreasonable, resulting in excessive pressure loss, resulting in the need to supply higher gas pressure. For example, the general pneumatic field terminal pressure can work stably as long as the air pressure is greater than 4.5bar, but due to the poor pipeline direction, the compressor must supply 6.5bar pressure. If the pipeline direction is optimized, only 5.8bar pressure is needed, which saves energy. The rate can reach about 10%.

　　 4. Insufficient energy storage at the end

　　In a production line, there are different types of gas utilization links, such as:

a. Continuous air use links, such as pneumatic motors (hand-held grinders), etc., require continuous and reliable pressure; b. Small-scale pulsed air use links, such as pneumatic screwdrivers, pneumatic pistons, etc., require continuous and reliable pressure; c. Large-scale pulsed gas use links, such as gas ash removal and injection equipment, require large energy storage; d. Open gas use links, such as glass cooling and purge links, require large flow rates and no clear pressure requirements.

Because the above-mentioned various gas-using links often coexist on the same section of the pipeline, pulsed gas-using equipment requires an instantaneous large gas supply. They will inevitably pull down the pipeline pressure, resulting in insufficient pressure in the continuous gas-using link, which requires The air supply side supplies more air pressure, which leads to a substantial increase in compressor energy consumption.

　　 Air pressure and air flow detection can be used to deploy air storage tanks at accurate locations to increase local energy storage and improve local air pressure, so that the overall air supply pressure is reduced, achieving better energy-saving effects.

　　 5. Take partial pressure air supply

　　In some areas, the supply demand of compressed air in the factory is divided into several types, as described in the previous chapter. For example, the end of the instrument air supply requires a pressure of 4.5bar, and the compressor is required to supply a pressure of 6bar, while the purge and cooling gas only requires a flow rate. As long as the pressure is higher than 2bar, it will be fine. Then, if the entire plant supplies a pressure of 6bar, Will cause a lot of waste. okmarts.com has good experience in this field, through expert inspection, reasonable design of partial pressure gas supply circuit, and achieve substantial energy saving. Some sites even save more than 50% energy.

　　6. ​​Gas component replacement and leak detection

The compressor system is a continuously operating whole. During the long-term operation of various gas components and joints, performance degradation, air leakage and other undesirable phenomena may occur. Each gas use point of the enterprise is tested to find the links with lower efficiency. , And replace it to achieve maximum energy saving.

　　 Compressor waste heat utilization and energy saving

　　 1. Compressor waste heat to make hot water

Use the hot oil and hot air during the compressor operation for heat exchange, transfer the heat to the soft water medium, and then transfer the heat of the soft water medium to the hot water used by the user. The two-stage heat exchange is realized Utilization of waste heat.

　　This kind of waste heat utilization method is mainly for the occasions with more compressors and more hot water demand.

　　 For example, various enterprises in the south have compressors that operate for a long time, and staff dormitories need hot water for bathing; coal mines have a large number of compressors running, and workers have a large amount of hot water for bathing.

　　 2. Compressor waste heat refrigeration

　　Using the heat energy during compressor operation to produce high-temperature hot water, and then using high-temperature hot water as a heat source to drive the lithium bromide unit for refrigeration, which can produce chilled water for the production link. For example, pharmaceutical companies use the waste heat of centrifugal compressors to produce hot water at 90 degrees Celsius, drive lithium bromide units for refrigeration, make up for the lack of chilled water, greatly reduce the utilization rate of refrigeration compressors, and have significant energy-saving effects. Electronic companies use the waste heat of compressors to produce 95 degrees Celsius hot water to drive lithium bromide refrigeration, and the chilled water produced is supplied to the air conditioning and production lines of the company’s production workshops.

　　 Compressor attached dryer for energy saving

　　In the chemical industry and other occasions, the moisture content of the compressed air is required to be high, so the use of a refrigerated dryer or a suction dryer to dry the compressed air will also bring additional energy consumption.

　　1. Cold dryer linkage

　　 In some sites, the cold dryer runs all year round and the operation mode is relatively extensive. Evaluate the humidity (dew point) of the compressed air and link the refrigeration dryer to achieve a better power saving effect.

　　2. Optimization of suction dryer

　　The general adsorption dryer has two kinds of energy consumption:

　　A. Loss of compressed air;

　　B. Power consumption of regenerative heating;

　　In some sites, the loss of the suction dryer is relatively large. Through the optimized suction dryer, the air consumption and power consumption can be greatly reduced, unnecessary loss and energy saving can be realized.

　　3. Smart trap

In many sites, in order to achieve drainage, the trap has not been carefully controlled. It is opened for a long time and there is continuous leakage. This kind of working method consumes a lot of energy, and it seems that a small leak is due to the gas produced by the compressor. The efficiency itself is not high, and compressed air is more precious, so the power consumption caused is quite amazing. Through intelligent trap control, the opening time of the trap is greatly shortened (by 90%), and continuous leakage is prevented. The payback period of this technology is very short.