Air compressor: air compressor selection
Air compressor: According to incomplete statistics, the power consumption of the compressed air system accounts for 10%-30% of the power consumption of the enterprise, and 96% of the energy consumption of the compressed air system is the power consumed by the compressor.
In the operation of most compressors, there are many complex problems such as low efficiency, unsatisfactory operation parameters, mismatched equipment, large pressure loss of pipe network, unscientific early selection, system leakage, artificial demand, improper use, improper system control and so on.
The low cost strategy of compressed air system should focus on energy saving and consumption reduction. Air compressor system consumes a lot of human and material resources in procurement and use, including personnel costs, procurement and installation costs, power consumption and maintenance costs. So, in the initial construction, how to plan and choose the air compressor system is energy saving and consumption reduction?
I. Common unreasonable phenomena of air compressor system
Purchase air compressor
When purchasing, we only considered the low price of the machine, and found that the quality was poor, the operation was unstable, and the downtime was long, resulting in the production line shutdown loss;
Purchase only consider the operation stability, ignore the proportion of energy consumption, resulting in a huge waste over time;
The procurement ignored the after-sales service quality of suppliers, trouble shooting could not arrive in time, and spare parts procurement was not convenient, which caused unnecessary losses.
Second, system organization
Air compressor capacity is too large, resulting in high waste of empty energy of air compressor;
Too much filter installation, large pressure loss, high energy waste;
Air compressor is not centralized gas supply, but distributed throughout the plant, independent pipeline, not only increases the cost of equipment purchase, but also increases;
Pipeline costs and operation and maintenance costs;
The ambient temperature of the air compressor room is too high, which is equivalent to reducing the efficiency of the air compressor, reducing displacement and increasing energy consumption. Every 10℃ increase in ambient temperature, the efficiency of the air compressor will be reduced by about 3%. Unreasonable piping arrangement, excessive elbow, increase pressure loss.
Iii. System control and management
The outlet pressure value of air compressor is set too high, resulting in energy consumption increase and waste. For every 1kg/cm increase in pressure, energy consumption increases by about 7%.
Multiple air compressors run at the same time for loading and unloading or capacity adjustment (partial load), increasing energy waste;
Machine maintenance is not good or overdue, small problems accumulate into big failures, machine life is artificially shortened;
The machine room environment is too dirty, resulting in frequent replacement of air compressor filters, oil filters, oil and gas separators and cooling oil;
Pipeline filter is not replaced in time, pressure loss is too large, serious energy waste;
I do not know whether the pipeline leakage is serious, so I use the newly bought air compressor to supplement the insufficient air volume, resulting in waste. According to the calculation of a hole hole of 7 kg/cm g and 10mm, it is assumed that the electricity fee is 1 yuan /kWh, and the electricity fee is 320,000 yuan wasted for 8000 hours a year.
Pay attention to energy saving of air compression system
1. LCC811 rules for air compression systems
LCC (Life cycle cost) is also called life cycle cost. 80% of this is for electricity, 10% for maintenance and 10% for purchases. So the air compression system concentrates 80% of the electricity bill.
2. Lean management of air compression system
The production of compressed air in the necessary quantity, pressure and quality when necessary.
3. Pay attention to the air compressor section
3.1 Is the selection of air compression system reasonable? Shall we directly bid according to the scheme designed by the design Institute, or shall we bid according to the low LCC cost according to the gas consumption, gas pressure and gas quality, without considering the matching type?
3.2 The necessity of Internet of Things cloud platform for air compression system
The energy saving of air compression system is not only an initial choice, but a continuous process. Management is managing data. Based on the data collected and analyzed in real time on the cloud platform, professional engineers can adjust the operating parameters and rules of the device in real time according to the fluctuation rules of pressure and gas consumption.