• 2024/10/22 11:07:39

How to save energy and reduce emission of air compressor?

Compressed air, as one of the power sources of manufacturing enterprises, needs to be continuously operated to ensure the stability of the supply air pressure, which is the basic conditions for the production and operation of enterprises, and as the main manufacturing equipment, the air compressor unit is the core equipment to undertake this task, and constantly needs continuous and reliable operation to ensure trouble-free and stable operation. Since it is running equipment, it needs power supply to run, and large power consumption is the core of cost increase.

Below I will introduce some tips that can make air compressors energy saving and emission reduction, enterprises can take measures and improve according to their own situation.

First, replace the energy-saving compressor

In today's industrial field, screw compressors have become the largest type of compressor due to their rugged, easy to maintain characteristics, and are very versatile. However, the energy efficiency of screw compressors still hovers at a low level, and only about 20% of the electricity input to screw compressors is converted into effective compressed air power, and the rest is converted into heat. If the efficiency of the screw compressor itself is improved to achieve energy-saving screw compressors, then great benefits will be obtained.

Screw compressors or centrifugal compressors of higher energy efficiency can be selected through selection and calculation, but the amount of investment in this way is relatively large, unless the user enterprise has the intention, otherwise it is not recommended.

Second, gas transmission pipeline and end optimization energy saving

Once the compressed air is produced, it needs to be transported to the use of the gas storage tank and pipeline, and in the transmission process, there are often problems in the pipeline, which increase energy consumption and cause unnecessary waste. The energy saving of compressor system can be realized greatly through the energy saving method of optimizing the gas link of the pipeline and the end.

1. Insufficient capacity of gas storage tank

In the application site, the problem often occurs is that the capacity of the gas storage tank is insufficient, because the capacity is small, the energy storage effect is poor, and the pressure fluctuation is large, resulting in repeated loading and unloading of the compressor, forming a large amount of energy waste. By increasing the gas storage tank, the single unloading time exceeds a certain time, then the compressor unloading power consumption will decrease, forming an energy-saving effect.

2. Right Angle elbow

The right Angle elbow at the connection of the pipeline has a great damage to the energy efficiency, and the reasons are:

A. The right Angle elbow forms a gas impact, and the local pressure increases, causing the compressor to continue to operate in a high pressure state, and it is easy to unload.

b, the right Angle elbow causes the flow resistance to increase, forming an additional work point.

For the right Angle elbow of the compressor outlet, the pressure of 0.5bar can be depleted in serious cases. If the 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 harm can be seen. Rational optimization of pipeline connection points can significantly reduce the energy loss, and this part of the loss is almost eliminated.

3. The pipe goes improperly

After the compressed air is sent out from the unified gas storage tank, it is transported to the gas link through various pipelines. The efficient transmission forms are single point Daisy chain and multi-point ring. However, the general user site because of one-time investment savings and other reasons, the direction of the air pipeline is often unreasonable, resulting in excessive pressure loss, resulting in a higher gas pressure must be supplied. For example, the general pneumatic field end pressure can work stably as long as it is greater than 4.5bar, but due to poor pipeline direction, the compressor must supply 6.5bar pressure, if the pipeline direction optimization, only 5.8bar pressure can be supplied, and the energy saving rate can reach about 10%.

4. Insufficient peripheral energy storage

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

A. Continuous use of gas links, such as air motors (hand-held grinding machines), requires continuous and reliable pressure;

b, small-scale pulse type gas links, such as pneumatic screwdriver, pneumatic piston, etc., require continuous and reliable pressure; c, large-scale pulse type gas links, such as gas ash removal, injection equipment, etc., require large energy storage;

d, open gas links, such as glass cooling, purging links, etc., require large flow, no clear requirements for pressure.

Since the above various gas links often coexist on the same section of pipeline, pulse gas equipment needs a large instantaneous gas supply, they are bound to pull down the pipeline pressure, resulting in continuous gas links not enough pressure, which requires the gas supply end to supply greater pressure, resulting in a significant increase in compressor energy consumption. By detecting air pressure and air flow, gas storage tanks can be deployed in the exact position to increase local energy storage and improve local air pressure, so that the overall gas supply pressure can be reduced, and better energy saving effect can be achieved.

Third, the compressor waste heat utilization energy saving

The production process of compressed air is more complex, in the process of gas compression, the degree of heating is high, often reaching about 100 degrees Celsius, and only about 20% of the energy consumed by the compressor is converted into compressed air power, and the remaining 80% is converted into heat. Therefore, the waste heat utilization value of the compressor is often high.

1. Compressor waste heat to produce hot water

Use the hot oil and hot air during the operation of the compressor for heat exchange, transfer the heat to the soft water medium, and then transfer the heat of the soft water medium again to the hot water used by the user, two-stage heat exchange, to achieve the utilization of waste heat. This method of waste heat utilization is mainly for occasions with more compressors and more hot water demand. For example, various enterprises in the south have compressors running for a long time, and the staff dormitory needs hot water bath; Coal mine, with a large number of compressors running, and workers bathing hot water is large.

2. Compressor waste heat cooling

Use the heat energy during the operation of the compressor to produce high temperature hot water, and then use high temperature hot water as a heat source to drive the lithium bromide unit refrigeration, which can produce frozen water to supply the production link. For example, pharmaceutical companies use the waste heat of centrifugal compressors to produce hot water to drive the refrigeration of lithium bromide units, make up for the shortage of frozen water, greatly reduce the utilization rate of refrigeration compressors, and save energy. Electronics companies use the waste heat of compressors to produce hot water, drive lithium bromide refrigeration, and produce chilled water to supply air conditioners and production lines in production workshops.

In short, the energy-saving measures of screw air compressors and middle and high pressure air compressors involve many aspects, which need to be comprehensively considered from the aspects of purchase, operation parameter adjustment, energy-saving technology application and maintenance management. Only comprehensive measures can be taken to minimize energy consumption and improve the operating efficiency of air compressors.