According to incomplete statistics, the power consumption of air system of air compressor accounts for 10% - 30% of the power consumption of enterprises, and 96% of the energy consumption of compressed air system is the power consumption of compressor.
In most air compressors, there are many complex problems, such as low efficiency, unsatisfactory setting of equipment operation parameters, equipment mismatch, large pressure loss of pipe network, unscientific early selection, system leakage, human demand, incorrect use and improper system control.
The low cost strategy of compressed air system should start from energy saving. Air compressor system consumes a lot of manpower and material resources in purchase and use, including personnel expenditure, purchase and installation cost, power consumption and maintenance cost. So how to reasonably plan and select the initial air pressure system is energy saving and consumption reduction?
Common unreasonable phenomena of air compressor system
Purchase of air compressor
·When purchasing, we only consider that the machine is cheap, the quality is too poor, the operation is not stable and the downtime is long, which results in the loss of production line downtime;
·When purchasing, only the stability of operation is considered, and the ratio of energy consumption is ignored, which leads to huge waste;
·When purchasing, the after-sales service quality of the supplier is ignored, the troubleshooting cannot arrive in time, and the purchase of spare parts is inconvenient, all of which cause unnecessary losses.
System planning
·The capacity of air compressor is too large, resulting in high waste of no-load energy of air compressor;
·Too much filter installation, large pressure loss, high energy waste;
·The air compressor is not centralized air supply, but distributed in all parts of the plant. The pipeline is independent, which not only increases the cost of equipment purchase, but also increases the cost;
·Pipeline cost and operation and maintenance cost;
·The high ambient temperature in the air compressor room reduces the efficiency of the air compressor, reduces the exhaust volume and increases the energy consumption; every 10 ° C increase in the ambient temperature reduces the efficiency of the air compressor by about 3%. Unreasonable pipeline layout, too many elbow joints, increase pressure loss.
System control and management
·The outlet pressure of the air compressor is set on the high side, resulting in the increase of energy consumption and waste. For every 1 kg / cm 2 of pressure increase, energy consumption increases about 7%;
·Multiple air compressors operate at the same time for loading and unloading or capacity adjustment (partial load), increasing energy waste;
·The maintenance of the machine is not good or overdue, small faults accumulate into major faults, and the service life of the machine is shortened artificially;
·The environment of the machine room is too dirty, resulting in frequent replacement of the filter, oil filter, oil-gas separator and cooling oil of the air compressor;
·The pipeline precision filter is not replaced in time, resulting in excessive pressure loss and serious energy waste;
·Pipeline leakage is serious, but I don't know, to buy a new air compressor to supplement the insufficient air, resulting in waste. Based on the calculation of a 7 kg / cm2 g, 10 mm aperture leakage, assuming that the electric charge is 1 yuan / degree, the electric charge of 320000 yuan will be wasted in 8000 hours a year.
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