7 Simple But Effective Ways To Save Energy in Air Compressors

As one of the power sources of manufacturing enterprises, compressed air needs to be continuously operated 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 required to ensure trouble-free and stable operation. Since it is an operating device, it needs power supply to operate, and the large power consumption is the core of cost increase. At the same time, in the process of continuous gas supply, whether there is leakage or invalid use of the entire gas supply pipe network system within the enterprise, so that the produced compressed air leaks in vain, which is another core of cost increase. In order to effectively reduce the use cost of air compressor units, the following points are explained.

1. In the technical transformation of equipment, it is necessary to pay attention to high-efficiency units, such as replacing piston machines with screw air compressors, which is the development trend of equipment. Although the industry has entered the era of screw machines for nearly 20 years, 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 been emerging, and various companies are rushing to launch products that exceed the national energy efficiency grade standards.

2. Leakage control of the entire pipe network system during the use of compressed air. The average leakage of compressed air in factories is as high as 20-30%, so the main work 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, 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. It is a pity that the ineffective use of leaked compressed air, a power source produced by energy consumption, electricity and water, makes it leak in vain. I hope that it will attract the attention of enterprise managers.

3. Every time the compressed air passes through a device, there will be a loss of compressed air, and the pressure of the air source will be reduced, and the pressure drop treatment needs to be carried out, that is, a pressure gauge is set up in 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. If there is any problem, it needs to be maintained in time. (Each increase of one kilogram of pressure increases the energy consumption by 7%-10%).

      When selecting the type of compressed air equipment and evaluating the pressure demand of the gas-consuming equipment, it is necessary to comprehensively consider the air supply pressure and air supply volume, and do not blindly increase the air supply pressure and total power of the 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 air-consuming equipment only need 3 to 4 bars, and a few manipulators only need more than 6 bars. (For every 1 bar lower in pressure, energy saving is about 7-10%). For enterprise gas equipment, the production and use can be guaranteed according to the gas consumption and gas pressure of the equipment.

4. Equipment selection needs to use high-efficiency compressors. According to the production gas consumption of enterprises, it is necessary to consider the use of gas during peak and valley periods. Variable working conditions can be used, and high-efficiency permanent magnet variable frequency screw air compressors are used, which is beneficial to Energy saving.

     At present, the domestic leading high-efficiency permanent magnet variable frequency screw air compressor, its permanent magnet motor saves more than 10% of energy than the general motor, has constant pressure air, will not cause waste of pressure difference, how much air is used to pump as much air, no need to load and unload, etc. Advantage. It can save more than 30% energy than ordinary air compressors. The variable frequency production gas is especially suitable for modern production and manufacturing. Centrifugal units can also be used in units with large gas consumption, which can alleviate the problem of insufficient peak gas consumption with high efficiency and large flow.

5. In the era of Internet big data, centralized control of multiple devices is a good way to improve modern enterprise management methods. Centralized linkage control of multiple air compressors can avoid the stepped exhaust pressure rise caused by the parameter setting of multiple air compressors, resulting in waste of output air energy. The joint control of multiple air compressor units, the linkage control of post-processing equipment and facilities, the monitoring of the flow 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 in equipment maintenance and cleaning, increase the heat dissipation effect of the air compressor, the exchange effect of heat exchangers such as water cooling and air cooling, maintain oil quality, etc., all of which can reduce energy loss. According to the operating principle of the air compressor, the air compressor inhales natural air, and after multi-stage treatment, multi-stage compression forms high-pressure clean air to supply other equipment. During this whole process, the air in nature will be continuously compressed and absorbed most of the heat energy converted from electrical energy, and the temperature of the compressed air will increase accordingly. The continuous high temperature is detrimental to the normal operation of the equipment, so it is necessary to continuously cool the equipment, and at the same time The re-inhaled natural air reduces the intake air temperature and increases the intake air volume, which is an ideal state.

7. Waste heat recovery during compression. Air compressor waste heat recovery generally uses high-efficiency waste heat recovery equipment to heat cold water by absorbing waste heat from air compressors without additional energy consumption. It mainly solves the problems of employees' living and industrial hot water, and saves a lot of energy for enterprises, thereby greatly saving the output cost of enterprises.