Commonly used energy saving points for air compressors

Commonly used energy saving points for air compressors

Air compressors are recognized as energy-intensive process equipment, and screw compressors are no exception. However, in the daily operation process, the energy consumption of screw compressors often does not attract enough attention from operating units. The main reason:

　　 One is not clear; the other is that there is no effective control method. Only by thoroughly understanding and trying to control, can the screw compressor be used efficiently.

　　 A 40-cubic screw compressor we came into contact with had an increasingly louder noise during its operation, because most of its overhaul and maintenance depended on the manufacturer, but it was mentioned many times without self-inspection. Occasionally, when I opened the door of the case for observation, it was found that one of the sewage pipe screws fell off, and the sound suddenly decreased after installing it. However, after comparing with other compressors, the noise of this compressor is still louder. After the factory personnel came, after observation, we could not find out the reason. After careful observation, we thought that there were many small leaks inside the compressor, and this kind of leakage that is difficult to observe is the source of noise.

　　This kind of leakage not only increases the noise, but more importantly, the leakage causes a waste of energy, which leads to a decrease in air output and an increase in cost. Some people may think that some small leaks are normal and will not have much impact. There are many people who hold this view, but in real life we ​​know that a needle has a big eye and a strong wind. Due to leaks, especially pipeline leaks, we often fail to obtain a statistical balance between borrowers and lenders. The loss is gone? Obviously it is leaked. Who will pay for the missing part? Let users pay, which will inevitably increase the cost of users. This phenomenon can be solved well in small companies, but in large companies, it is divided In the case of independent calculations by the factory, new contradictions will inevitably arise. Because each branch can use the meter at the entrance to calculate the compressed air flow, the amount of air used can be calculated by itself. The sum of the air consumption of each branch is lower than the air output of the air compressor station, and this part of the difference is caused by the leakage. The cost of the leakage is added to the user, and the user will definitely not buy it. In this way, the air compressor station will have to bear the burden on its own, and it will lose money, and if it is counted on the user, it will cause conflicts between the two parties.

　　 Therefore, energy saving is of great significance to screw compressors, and we must have a clear understanding of it.

　　 Air compressor energy saving is mainly to improve economic efficiency, improve equipment integrity and utilization rate, reduce operating costs, improve compressed air quality and output, reduce maintenance costs, and create a good working environment.

According to relevant statistics, the largest piece of compressor energy consumption is electrical energy consumption, which accounts for 77% of the total consumption, followed by maintenance costs, which account for 18% of the total consumption, while equipment investment only accounts for 5 of the total cost. %.

　　 From the above figures, it is not difficult to see that the power consumption of the compressor is quite amazing. A compressor costs as little as tens of thousands of yuan, and as many as millions, but the purchase cost is only 5%, which shows the huge power consumption figure.

Let's discuss another set of figures. What is the utilization rate of compressed air? According to estimates, only 60% of compressed air can be sent out, while 30% is leakage, 15% is artificially requested, and the other 5%. It is an operational problem. However, in actual work we also found a phenomenon, that is, whether users need compressed air or not, especially in a very large enterprise like ours, even if there is no production task, it is necessary to ensure that there is enough in the air supply pipeline for 24 hours. Compressed air under pressure is like domestic water pipes. If the pipes are not adequately protected, the supply of power working fluid will be affected. This is a common problem of compressed air and other power sources and cannot be changed. In this case, the amount of compressed air that can be actually used by the user can be imagined.

　　In this case, what we can touch is the reason for the energy consumption of the screw compressor. Only by targeted solutions can we continue to improve energy efficiency.