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How to estimate how much gas a factory will use

2026-04-15Views:

To estimate the usage of compressed air in the plant, a comprehensive analysis of equipment list, process parameters and system losses shall be carried out. The following is a systematic estimation process based on industry practice:

1. basic data collection

  1. general survey of gas-using equipment
    • prepare "Compressed Air Equipment Account", record the equipment name, model, quantity, rated power (kW) and single gas consumption (m & sup3;/min)
    • typical equipment gas reference value:

      Device Type gas consumption per unit (m & sup3;/min)
      pneumatic wrench0.3-0.8
      sandblasting machine2.0-5.0
      bottle blowing machine1.5-3.0
      CNC machining center0.8-1.2
  2. production process analysis
    • draw the Gas Process Flow Chart and mark the gas pressure (bar), flow rate (m & sup3;/min) and usage frequency of each process.
    • Identify continuous gas equipment (e. g. pneumatic conveying) and intermittent gas equipment (e. g. spot welder)
  3. measurement of pipe network parameters
    • measure the main pipe diameter (DN), length (m) and current pressure loss (& Delta;P)
    • detect the leakage point of the existing system, and use ultrasonic leak detector to locate

2. gas consumption calculation model

  1. theoretical calculation method
    • gas consumption of single equipment:
      Q equipment = 60 × & eta; Pneumatic P rated × k
      (k: air consumption coefficient of equipment, 0.2-0.3 for pneumatic tools; & eta; pneumatic: pneumatic efficiency, 0.7-0.8)
    • total gas consumption:
      Q total = & sum;Q equipment × t usage coefficient
      (T usage coefficient: 1.0 for single shift, 1.8 for double shift and 2.5 for three shift)
  2. actual measurement verification method
    • install a gas flow meter in the main pipeline, monitor continuously for 72 hours, and record the peak and valley values
    • typical industry air density reference:

      Industry type air density (m & sup3;/min · output value of ten thousand yuan)
      auto Parts0.8-1.2
      food & Beverage0.5-0.9
      textile printing and dyeing1.0-1.5
  3. system Loss Correction
    • leakage loss: total gas consumption ×(5-15%)
    • pressure correction factor:
      Kp = P actual P rated × 100%
      (For every 1bar decrease in pressure, the flow rate is reduced by about 7%)

3. special condition adjustment

  1. pulse gas correction
    • for pulse gas equipment such as sand blasting and purging, the peak factor (1.5-2.0) shall be multiplied.
    • When the gas storage tank is configured, the tank capacity shall meet the following requirements:
      V storage ≥ & Delta;P allows q pulse × t pulse
  2. temperature correction
    • gas consumption increase in high temperature environment (>40 ℃):
      Q correction = Q theory ×(1+0.03 ×(T & minus;20))
  3. altitude Correction
    • for every 1000m elevation, the air density decreases by about 10%, and the air consumption needs to be increased:
      Q correction = Q theory × 1 & minus;0.0001 × H1
      (H: altitude, m)

validation of 4. estimation results

  1. unit output value method
    • compared with the gas consumption per unit of output value in the same industry, if the deviation of the estimated value is more than 30%, the equipment list shall be reviewed.
  2. Pipe network pressure test
    • measure the pressure at the end with a gas point. If it is lower than the rated pressure by more than 20%, the system capacity needs to be reevaluated.
  3. economic analysis
    • calculate the loading rate of air compressor (ideal range 70-90%), if long-term <60%, consider configuring frequency conversion model

5. optimization recommendations

  1. graded gas supply system
    • high-pressure equipment (>0.7MPa) and low-pressure equipment are supplied separately to reduce throttling losses.
  2. waste heat recovery
    • the calorific value of the air compressor accounts for 80-90% of the input power, and the waste heat recovery device can be configured for boiler water preheating
  3. intelligent control
    • install intelligent flow controller to realize real-time monitoring of gas consumption and leakage alarm

through the above method, the plant compressed air demand model can be established. It is recommended to review every 2-3 years, especially after process changes or equipment increases or decreases. For new plants, the analogy method can be used to reserve 20-30% of the expansion capacity by referring to the gas consumption data of the same type of plant.

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