According to incomplete statistics, the power consumption of the compressor air system accounts for 10%-30% of the company's power consumption, and 96% of the compressed air system consumption is the power consumed by the compressor.
In the initial operation of the compressor, the efficiency is low, the equipment operating parameter settings are not satisfactory, the equipment does not match, and the pressure loss in the pipe network is large.
Early selection is unscientific, the system is large, the personnel needs are large, the use is incorrect, the system control is improper, and other complicated problems.
The air compressor system consumes a lot of manpower and material resources in procurement and use, including personnel expansion, purchase and installation costs, power consumption, and maintenance costs. So, how to reasonably plan and select the initial air compressor system to save energy and reduce energy consumption?
Common unreasonable phenomena in air compressor systems
Buy air compressor
1.1 When purchasing, only consider the cheap price of the machine. It is found that the quality is too poor, the operation is unstable, and the downtime of the failure is long, which causes the loss of the production line;
2. When purchasing, only consider the stability of the operation, which violates the expected ratio and will cause huge waste over time;
3. Violation of the supplier's after-sales service quality during the purchase process, failure to arrive in time for troubleshooting, inconvenience in purchasing spare parts, etc., are all
4. Budget loss.
System planning
1. The capacity of the air compressor is too large, resulting in a large waste of air compressor no-load energy;
2. Too many filters are installed, the pressure loss is large, and the energy waste is high;
3. The air compressor is not a centralized air supply, not distributed in the entire factory, but an independent pipeline, which not only increases the equipment purchase cost but also increases the cost;
(4) Pipeline fees and operation and maintenance fees;
5. The ambient temperature of the air compressor room is too high, which is equivalent to reducing the efficiency of the air compressor, and the exhaust volume is continuously reduced; the ambient temperature per liter
A high temperature of 10°C is equivalent to reducing the efficiency of the air compressor by about 3%.
System control and management
1. The outlet pressure value of the air compressor is set too high, resulting in increased energy consumption and waste. Every time the pressure increases by 1 kg/cm2, the energy consumption will increase by about 7%;
2. Simultaneous operation of multiple air compressors to increase and increase airflow, or simultaneous capacity adjustment (partial load) operation, which increases energy waste;
3. The machine is poorly maintained or overdue without maintenance, minor faults accumulate into major faults, artificially shortening the life of the machine;
4. The engine room environment is too dirty, and the air compressor filter, oil filter, oil and gas separator, and cooling oil need to be replaced.
5. The precision filter of the pipeline is not replaced in time, causing excessive pressure loss and a serious waste of energy;
6. The pipeline leakage is serious and unknowingly, using a new air compressor to supplement the insufficient air volume, causing waste. The weight is 7 kg/cm2
The leakage amount is 10mm, and the estimated electricity bill is 1 yuan/kWh. 8,000 hours a year will waste 320,000 yuan in electricity bills.
Focus on energy saving of air compressor system
1. LCC811 rule of the air compressor system
Therefore, the electricity cost is 80%, the maintenance cost is 10%, and the purchase cost is 10%. Therefore, the focus of the air compressor system is 80% of the electricity cost.
2. Lean management of air compressor system
This means generating the necessary quantity, the necessary pressure, and the necessary quality of compressed air when necessary.
3. The key to energy saving of air compressor
3.1 Is the choice of air compressor system reasonable? Whether it is directly bidding according to the plan designed by the design institute, or bidding according to the gas volume and pressure,
Did you use the gas quality that is not related to the matching type and the lowest cost of the LCC bid?
3.2 The necessity of IoT cloud platform in an air compressor system
According to the cloud platform, the energy saving of the air compressor system is not only the initial choice. Energy-saving is a continuous process, and management is the management of data.
Real-time data collection and analysis, according to the fluctuation law of pressure and gas volume, the mobilized engineer can adjust the operating parameters and laws of the equipment in real-time.
