Necessary Conditions for Selection of Air Compressor

In the operation of most compressors, there are complex problems such as low efficiency, unsatisfactory equipment operation parameter setting, equipment mismatch, large pressure loss of pipe network, unscientific early selection, system leakage, artificial demand, incorrect use and inappropriate system control.

The low-cost strategy of compressed air system should start with energy saving and consumption reduction. The air compressor system consumes a lot of manpower and material resources in the procurement and use, including personnel expenses, purchase and installation costs, power consumption and maintenance costs. So how can the initial air compressor system be reasonably planned and selected to save energy and reduce consumption?

Common Unreasonable Phenomena of Air Compressor System

the purchase of air compressor

when purchasing, only consider the cheap price of the machine, and find that the quality is too poor, the operation is unstable, and the downtime is long, resulting in the loss of production line downtime;

when purchasing, only consider the operation stability, ignoring the energy consumption ratio, resulting in huge waste over time;

when purchasing, the supplier's after-sales service quality was ignored, the failure of troubleshooting to arrive in time, and the inconvenience of purchasing spare parts caused unnecessary losses.

System Planning

the capacity of the air compressor is too large, resulting in high waste of no-load energy of the air compressor;

excessive installation of filters, large pressure loss and high energy waste;

the air compressor is not centralized gas supply, but distributed in all parts of the plant, and the pipeline is independent, which not only increases the equipment purchase cost, but also increases;

pipeline costs and operation and maintenance costs;

the ambient temperature of the air compressor room is too high, which is equivalent to reducing the efficiency of the air compressor, reducing the exhaust volume and increasing the energy consumption. Every 10°C increase in the ambient temperature is equivalent to a 3% reduction in the efficiency of the air compressor. Pipeline layout is unreasonable, elbow joints too much, increase the pressure loss.

system control and management

the air compressor outlet pressure value is set too high, resulting in increased energy consumption and waste. For every 1 kg/cm increase in pressure, energy consumption increases by about 7%;

multiple air compressors at the same time for loading and unloading action or at the same time for capacity adjustment (partial load) operation, increase energy waste;

the machine is not well maintained or not maintained after expiration, minor defects accumulate into major failures, and the life of the machine is artificially shortened;

the environment of the machine room is too dirty, resulting in frequent replacement of the air compressor filter, oil filter oil and gas separator and cooling oil;

the precision filter of the pipeline is not replaced in time, resulting in excessive pressure loss and serious energy waste;

the pipeline air leakage is serious and unknown. A newly purchased air compressor is used to supplement the insufficient air volume, resulting in waste. Based on a 7kg/cmg, 10mm aperture leakage calculation, assuming that the electricity charge is RMB 1 yuan/degree, 8000 hours a year will waste 320000 RMB electricity charge.

Focus on energy saving of air compressor system

1. LCC811 rule of air compressor system

LCC (Life Cycle Cost, or LCC), also known as life cycle cost. Of these, 80% are electricity costs, 10% are maintenance costs and 10% are purchase costs. Therefore, the focus of the air compressor system is on 80% of the electricity cost.

2. Lean management of air compression system

refers to the production of the necessary quantity, the necessary pressure, the necessary quality of compressed air when necessary.

3, the focus of air compressor energy saving

is the type selection of 3.1 air compressor system reasonable? Is it direct bidding according to the scheme designed by the design institute, or is it based on the amount of gas used, the pressure of gas used and the quality of gas used, with no limitation on the type of matching and the lowest cost of LCC?

Necessity of Internet of Things Cloud Platform on 3.2 Air Compression System

energy saving of air compressor system is not only the initial selection, energy saving is a continuous process. Management is to manage data. According to the real-time collection and analysis of data from cloud platform, professional engineers can adjust the operating parameters and laws of equipment in real time according to the fluctuation law of pressure and gas consumption.