How much compressed air is needed for an annual output of 400000 cubic meters of aluminum alloy

Conclusion: The annual output of 400000 tons of aluminum alloy requires about 100 to 110 cubic meters of compressed air per minute, and the total annual consumption is about 10 million to 11 million cubic meters.

How did this number come about. There is an actual project data for reference: the workshop with an annual output of 150000 tons of aluminum alloy ingots has a calculated compressed air load of 40 cubic meters per minute and an annual consumption of 3.82 million cubic meters. According to this ratio, the scale of 400000 tons is about 2.67 times that of it, so the gas demand is about 107 cubic meters per minute, and the annual consumption is about 10.19 million cubic meters.

Compressed air is mainly used in these places in aluminum alloy production: mixing and blowing refining in smelting process, sand blowing cleaning and pneumatic control in casting process, feed gas of nitrogen station (aluminum alloy smelting protection needs a large amount of nitrogen, while nitrogen making machine needs compressed air as raw material), and various pneumatic tools and instruments. Among them, the amount of nitrogen is very large. The annual nitrogen consumption of the first phase of the project alone is close to 50000 cubic meters, and the total of the two phases is 86000 cubic meters. This is only nitrogen, not compressed air itself.

Water-lubricated oil-free air compressors are very suitable in this scenario. Aluminum alloy castings have high requirements for gas cleanliness. The gas discharged from the traditional oil-injected air compressor will contaminate the surface of the casting. When the water-lubricated oil-free air compressor works, pure water is used instead of oil for lubrication and sealing. The discharged gas is completely oil-free, and because the cooling effect of water is better than that of oil, the exhaust temperature is only about 40 ℃, which belongs to isothermal compression. The gas production per unit horsepower is about 15% higher than that of a dry machine. Cooperate with the air-water separator and dryer to remove the moisture, the air pipe is clean and dry oil-free air, the casting quality is more guaranteed.

In the actual selection, it is recommended to match 110 cubic meters per minute, plus a margin of about 20% to deal with production fluctuations and pipeline leakage. That is to say, with a water-lubricated oil-free air compressor of about 130 cubic meters per minute, plus a cold dryer or a suction dryer for post-treatment, it is basically enough.