Necessity of energy saving renovation
As an indispensable equipment for production enterprises, air compressors often consume a large amount of electricity in industrial and mining enterprises, and often account for 50% of the electricity consumption of the whole plant. Its high operating energy consumption cost virtually increases the operation of the enterprise Cost; more seriously, the selection of the air compressor system is old, the index deviates from the actual (too large or small), the main engine is worn, the parallel supply of low-power multiple devices, the unreasonable pipeline layout, multi-point leakage, etc. Can cause huge energy waste...
1. Screw air compressors replace piston air compressors
Compared with traditional piston compressors, screw air compressors have the advantages of simple structure, small size, high reliability, stability, and simple maintenance...
2. Adopt high performance compressor
According to different working conditions, the use of high-performance centrifugal compressors, permanent magnet variable frequency screw air compressors or permanent magnet variable frequency two-stage air compressors is conducive to energy saving. At present...
3. Air compressor pipeline control leakage
Generally speaking, the average leakage of compressed air in factories is as high as 20~30%, so the important work of energy saving is to control leakage.
The leak points include: all pneumatic tools, hoses, joints, valves, a small hole of 1 square...
Leaks in factories typically account for 10% to 30% of gas supply, and can be as high as 50% in poorly managed factories
Air leaks cause power loss
Equipment energy-saving renovation
Amount of leakage
|Power loss||Converted to air compressor
Annual power consumption
|Electricity fee (yuan/year)
(at 0.8 yuan/degree)
4. Pressure drop management
Unreasonable pipeline planning, corrosion of the inner wall of the pipeline, and small selection of the pipe diameter will all cause pressure loss in the process of gas transportation...
5. Pressure requirements of gas equipment
In the case of ensuring production, the exhaust pressure of the air compressor should be adjusted as low as possible, or a model with matching pressure should be selected...
6. Centralized Control
The centralized linkage control of the air compressor can automatically start/stop the air compressor according to the actual gas consumption, and change the stop sequence ...
7. Reduce the intake air temperature of the air compressor
Because the internal temperature of the general air compressor station is higher than that of the outdoor, outdoor gas extraction can be considered. Do a good job in equipment maintenance...
Aineng (AE) is committed to the development and research of compressor energy-saving technology, has strong professional strength and rich experience, and provides systematic energy-saving renovation solutions and one-stop services
Retrofit case study
The air compression system of a company mainly includes 6 sets of 90kW single-stage screw air compressors and their refrigerated dryers. The operation mode is 4 uses and 2 backups, which are respectively arranged in two air compressor rooms. Each air compressor There are 3 air compressors in the house, and its energy consumption reaches 20% of the total energy consumption of the enterprise.
AE engineers carry professional measurement equipment to conduct detailed surveys on user sites, collect data, and analyze the causes of energy consumption
System energy-saving renovation plan
According to the current survey situation and collected data, Aineng technical engineers conduct comprehensive analysis and research, and formulate optimal solutions
Select a two-stage compression permanent magnet variable frequency air compressor with a specific power of 5.81kW/m3/min first-level energy efficiency. The operation mode is 2-use and 1-standby, and one of them is controlled by frequency conversion...
According to the existing production consumption and subsequent incremental calculation, three sets of 220kW two-stage compressed air compressor equipment are selected to replace the original equipment, which reduces the pressure loss of each equipment list and avoids causing the pressure of the pipeline network to be low and the air supply pressure of the...
Use the intelligent management system to monitor the air compressors under the system in real time, automatically control the operation status of the air compressors, reduce operating costs, provide energy-saving analysis reports of the air...
Through systematic planning and design, the configuration of pipelines, elbows and auxiliary devices is more reasonable, reducing the pressure loss of each gas supply pipeline. At the same time, more energy-saving aluminum alloy pipes are used...
Energy saving effect and economic benefit analysis
After systematic transformation, the energy consumption of the air compressor system has been reduced by nearly 30%, and the energy saving effect is remarkable, which greatly improves the economic benefits of customers.
Energy saving retrofit
|Running time h/day||24||24|
|Gas consumption/day (10,000 cubic meters)||12.44||12.44|
|Power consumption/day (10,000 kWh)||1.69||1.2|
|Electricity fee (yuan/kWh)||0.63||0.63|
|Electricity Fee/Year (yuan)||3.5 million||2.5 million|
|Amount of electricity bills saved (yuan)||1 million|
Improve the stability and reliability of the air compressor system in an all-round way, and reduce the consumption of energy and labor costs