Reasonably reduce the cost of air compressor

How to reasonably reduce the cost of the air compressor system? The cost of the air compressor system includes the purchase cost and the use cost, not only the initial purchase amount is large, but also the use cost of personnel expenses, purchase and installation costs, power consumption, maintenance and maintenance, etc. How to reasonably reduce the cost of air compressor system has become the focus of enterprises to improve profits.

I. Common errors

(I) equipment procurement

1. When purchasing, only considering the cheap price of the machine, it is found that the quality is too poor, the operation is unstable, and the downtime is long, resulting in the loss of production line downtime.

2. When purchasing, only the operation stability is considered, and the energy consumption ratio is ignored, which causes huge waste over time.

3. Ignoring the after-sales service quality of suppliers during procurement, failure to arrive in time for troubleshooting, inconvenience in purchasing spare parts, etc., all caused unnecessary losses.

(II) system planning

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

2. Too many filters are installed, the pressure loss is large, and the energy waste is high.

3. The air compressor is not centralized gas supply, but is distributed throughout the plant, and the pipeline is independent, which not only increases the equipment purchase cost, but also increases the pipeline cost and operation and maintenance cost.

4. 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. For every 100°C increase in ambient temperature, the efficiency of the air compressor is reduced by about 3%.

5. The pipeline layout is unreasonable, the elbow joints are too much, and the pressure loss is increased.

(III) System Control and Management

1. The air compressor outlet pressure value is set too high, resulting in increased energy consumption and waste. For every 1kg/cm2 increase in pressure, the energy consumption increases by about 6%.

2. 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;

3. The machine is not well maintained or expired, minor defects accumulate into major failures, and the life of the machine is artificially shortened.

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

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

6. The air leakage in the pipeline is serious and unknown. A newly purchased air compressor is used to supplement the insufficient air volume, resulting in waste. Based on a 7kg/cm2g,10mm leak point, assuming that the electricity charge is RMB 1/degree, 8000 hours a year will waste 320000 RMB electricity charge.

II. The Right Method

(I) equipment procurement

1. Based on the ten-year service life, the equipment purchase cost accounts for about 5-10%, the maintenance cost accounts for about 5-10%, and the power consumption cost accounts for about 80-90%. Therefore, the first thing to consider when purchasing the machine

efficiency, energy saving means making money.

Operation stability and maintenance convenience are also important factors to consider.

3. Pay attention to the quality of after-sales service of suppliers.

(II) scientific planning

the size and number of air compressors should be carefully calculated and determined.

2. Post-processing equipment is not the more the better, but configured as needed.

3. The machine room should be selected as far as possible in a clean and well-ventilated place.

4. The pipeline layout shall minimize elbows and joints, and the pipe diameter selection shall be reasonable.

(III) System Control and Management

1. The outlet pressure of the air compressor is set as low as possible, just enough.

2. Try to let the air compressor full load operation, reduce the no-load time.

3. regular maintenance, prolong machine life.

4. Maintain the clean environment of the computer room.

5. Check and block the air leakage point in time.