How to calculate the gas consumption of a factory

The calculation of gas consumption in a factory usually involves multiple steps and factors. The following is a common calculation method:

1. clear calculation scope

• new factory: It is necessary to calculate the gas consumption of all gas equipment and consider possible future expansion, leakage and changes in equipment efficiency.
• Existing factory: It can be determined by actual testing to check whether the air consumption of the existing air compressor is sufficient, or by estimating the air consumption of the existing equipment.

2. gas consumption calculation

1. New factory

for new plants, the traditional method is to add up the gas consumption (usually in cubic meters per minute, or m & sup3;/min) of all gas-using equipment, and then consider adding a safety, leakage and development factor. This factor is typically used to account for possible future expansion, leakage, and changes in device efficiency. Specific steps are as follows:

• list all gas-using equipment: Including production equipment, auxiliary equipment and other equipment that require the use of gas.

• Find or calculate the gas consumption of each device:

  • for equipment with nameplate, it can be calculated directly according to the gas consumption marked on the nameplate.
  • For equipment with no nameplate or no gas consumption marked on the nameplate, it can be calculated by consulting the technical manual of the equipment, consulting the equipment supplier or using empirical formulas.

• Consider safety, leakage and development factors: Generally, this coefficient can be set from 1.1 to 1.3, depending on the actual situation of the factory.

• Calculate total gas consumption: Add the gas consumption of all equipment and multiply it by the safety, leakage and development factors.

2. Existing factories

for existing plants, the gas consumption can be calculated or verified by the following methods:

• actual test method:

  • measuring the volume of gas tanks and pipes: Including the volume of the gas storage tank and the volume of the pipeline between the compressor gas storage tank.
  • Full load operation of compressor: Ensure that the compressor runs at full load.
  • Close air valve and depressurize: Close the air valve between the air storage tank and the factory air system, and reduce the pressure of the air storage tank to a certain level (such as 0.48MPa).
  • Pump gas and record time: Close the air release valve quickly, and then record the time required for the air tank to pump air to the set pressure (such as 0.69MPa).
  • Calculation of compressor capacity: Use the formula C = T×PAV(P2 & minus;P1)× 60, where c is the compressor capacity (m & sup3;/min), v is the volume of the gas storage tank and pipeline (m & sup3;),P2 is the final pressure (MPa),P1 is the initial pressure (MPa), t is the time (seconds),PA is the atmospheric pressure (MPa, about 0.1MPa at sea level).

• estimation method:

  • add the gas consumption of all existing equipment.
  • Consider the gas consumption of post-treatment equipment (e. g. dryers, filters, etc.).
  • Consider the amount of leakage in the system, which can be determined by actual testing or empirical estimation.
  • Consider reserves to meet possible future expansion or peak gas demand.

3. consideration of influencing factors

• production process: Different production processes may have different gas requirements, such as high-temperature smelting, chemical reactions and other processes may require a large amount of gas.
• Equipment efficiency: The working efficiency of the equipment directly affects the consumption of gas. Old and inefficient equipment often consumes more energy, while efficient and energy-saving equipment can reduce energy consumption while ensuring production quality.
• Seasons and Climate: In some industries, gas demand will vary with seasons and climate. For example, heating demand increases in winter and cooling demand in summer may lead to changes in gas consumption.
• Leakage and loss: Leakage and loss in the system will increase the actual gas consumption. The equipment should be checked and maintained regularly to reduce leakage.

4. optimization recommendations

• technology upgrade: Introduce advanced production technology and equipment to improve energy efficiency. For example, energy-saving equipment, heat recovery technology, and the like are used.
• Energy Management: Establish a complete energy management system to monitor and analyze gas use in real time. Through data-driven management decision-making, the problem of energy waste is found in time, and the corresponding improvement measures are taken.
• Staff training: Strengthen employees' awareness of the importance of energy saving and consumption reduction, train them to use and maintain equipment correctly, and reduce energy waste caused by improper operation.

5. Conclusion

calculating the gas consumption of a plant is a complex process that requires consideration of multiple factors. The calculation and evaluation by reasonable method can provide scientific basis for the gas supply and management of the factory, reduce the operation cost and improve the production efficiency. For large plants or complex production processes, it is recommended to consult professional energy management experts or engineers to obtain more accurate gas consumption calculation methods and recommendations.