Optimization of air compressor control process parameters

1.1 suction pressure adjustment. Choosing the appropriate suction pressure can effectively reduce the compressor power consumption.

In general, the lower the suction pressure, the greater the energy consumption, especially the suction pressure of the compressor section.

Therefore, the suction pressure of the compressor can be appropriately increased, and a high-efficiency cyclone inlet separator can be added in one stage of suction to further eliminate the resistance of the air inlet pipe network, and a higher suction pressure can be obtained while ensuring sufficient processing air.

The pressure drop between the 1.2 compressor sections is reduced. The pressure drop between the compressor stages is also an important reason for the power consumption of the compressor.

In order to reduce the pressure drop between sections, high-efficiency heat exchangers can be used instead of interstage coolers to reduce unnecessary piping equipment and elbows, while improving operating conditions and reducing the degree of cooler fouling.

2 compressor structure design optimization

2.1 ternary flow impeller. The three-dimensional flow impeller is a kind of impeller structure designed for gas flow, which is generally used in large compressors.

The existing impeller can also be modified to have the characteristics of the three-dimensional flow impeller, and the performance of the impeller can be significantly improved.

The relevant theoretical research and trial operation prove that the use of the three-way flow impeller can improve the operating efficiency of the impeller by up to 10%, and the transformation cost of the original compressor impeller is low. However, it can significantly improve the production capacity of the equipment, improve economic efficiency, and the energy-saving performance of the compressor will also be significantly improved.

2.2 polished impeller. There is a direct relationship between the surface roughness of the impeller and the loss of the wheel set, and the surface finish of the impeller can be improved by precision casting, finishing and polishing.

There are many methods of impeller polishing, including sandblasting, polishing wheel, liquid polishing, abrasive belt polishing, etc. Generally, the appropriate polishing scheme is selected according to the actual structure and material of the impeller.

The impeller with large surface area can be polished by abrasive belt vibration, while the impeller with complex structure, multi-cavity and boss can be polished by liquid.

2.3 compressor return flow control. In order to avoid the surge problem of the compressor in operation, the compressor is provided with an anti-surge control mechanism. Under normal process parameters, the state curve is drawn by monitoring the operating parameters of the unit, and the surge control line is calculated according to the surge line, so as to obtain the surge flow control point. Through comparison with the inlet flow, the compressor return flow is controlled to ensure that the compressor can obtain sufficient working gas.

The manual control of compressor reflux can be transformed into automatic control, and a more accurate anti-surge control system can be applied to reduce the energy consumption of the unit.

Comprehensive optimization of 2.4 piping layout. In order to further reduce the pressure drop in the pipeline, it is necessary to adjust the pipeline layout to improve the rationality of the line layout, and the pressure loss can be used to evaluate whether the pipeline layout scheme is reasonable.

If the pressure difference between the inlet pressure and the outlet pressure does not exceed 5%, the pipeline layout planning of the compressor system is more scientific.

In the pipeline, the equipment structural parts that can cause pressure loss mainly include desiccant, cooler, control valve, elbow, etc. The pressure loss of desiccant, control valve and cooler can be measured according to the pressure loss standard. The pressure loss of elbow is approximately 8~10 times of the long pressure loss of equal diameter pipe. The total pressure loss of pipeline can be reduced by accurately calculating the total pressure loss of pressure loss equipment.

In addition to optimizing the design, the daily use and maintenance of the compressor also have a great impact on the energy saving effect of the compressor.

In daily work, scientific control methods should be used to adjust the compressor, and preventive maintenance strategies should be used to reduce the failure rate of the compressor and maintain the normal performance of the compressor, so as to give full play to the energy-saving advantages of the compressor.