Provide professional services for energy-saving renovation of air compressors

As the global energy crisis continues to intensify, energy conservation issues have attracted widespread attention around the world. Air compressors are the main power source for the manufacturing industry. The power consumption of air compressors in my country has accounted for % of the total power generation
, while the power consumption of air compressors in industrial and mining enterprises accounts for % of the total power consumption
/>Above, some companies even reach %
. In the total cost of air compressor, energy consumption accounts for about %
. Therefore, air compressor energy saving is a top priority. The following are energy-saving methods for air compressors
. Energy-saving methods for air compressors
. How to save energy as much as possible when the air compressor is running is a hot issue that people pay attention to. Generally, the following methods can be adopted to achieve the purpose of energy saving
.
.
Improve transmission efficiency
. Air compressors often use belts
to realize the transmission between the motor and the compressor.
Although belts have the advantages of smooth transmission, they are usually It is necessary to choose the method of connecting multiple tapes in parallel. Each tape may have uneven load due to different tightness or errors in the pulley grooves, which reduces the transmission efficiency, wastes electric energy, and reduces the service life of the belt.
. Select high-quality, precise pulleys and tapes. Replace all tapes at once when the load is uneven. Carefully adjust the center distance during installation to ensure that all tapes are subject to the same tension, which can effectively improve its transmission efficiency. . However, the belt transmission method cannot completely eliminate the energy loss in the transmission. The coaxial structure of the rotor and the motor can completely solve this problem. It also increases the air volume operation and realizes speed control in the full range.
.
Reduce friction power consumption
. The size of the gap and lubrication between the piston and cylinder liner affect the efficiency of the air compressor. If the gap is too small, it will cause air leakage loss. If the gap is too small, effective lubrication will not be formed, which will increase friction loss and increase the energy consumption of the air compressor.
. Only with appropriate clearance can effective lubrication be maintained.
Measures to reduce friction power consumption include precise clearance control, timely replacement of worn piston rings, ensuring appropriate oil viscosity, rapid circulation, and regular maintenance. In addition, attention should be paid to changing the lubricating oil according to seasonal and climate changes, and choosing lubricating oil with low viscosity as much as possible under the premise of good lubrication performance.
.
Reduce pressure loss
. The air system includes air filters, suction and exhaust valves, coolers, etc., which can transport compressed air to the equipment. If there are problems such as disrepair or improper repair of the suction and exhaust valves, air leakage will occur, reducing the exhaust volume, thereby reducing the operating efficiency of the air compressor.
. To reduce pressure loss, first of all, we must try to reduce the flow resistance and pressure loss of the gas system while satisfying the process, such as installing as few valves as possible, making the suction management as short as possible, etc. Secondly, using large diameter pipes The air circuit system and low-speed air supply method must again reduce internal and external leakage of the equipment and reduce the clearance volume. Fourthly, high-quality pneumatic components must be used. For example, the suction and exhaust valves should have good sealing performance and low resistance, and the air filter should be selected Fifth, the installation and daily management of new type filter filters, etc. should be carried out, and regular inspection and maintenance should be carried out to ensure the safe and reliable operation of the gas circuit system.
.
Improve heat exchange performance
. There are three types of air compressor compressed gas: isothermal, adiabatic, and variable compression. In theory, isothermal compression consumes the least energy, but in actual operation, it is much Variable compression.
. In order to reduce energy consumption during the compression process, cooling efficiency needs to be improved. There are intercoolers and aftercoolers in the cooling water system, which improves the performance of the intercooler and can make the secondary intake air temperature closer to the temperature under isothermal compression to ensure perfect backcooling. Cooler performance can be improved by lowering the cooling water temperature, increasing the flow rate, removing sediments in pipes and equipment, and using water treatment agents to improve water quality.
. Properly configure water pumps, control water consumption, reduce waterway losses, and effectively reduce power consumption. In an open cooling water system, energy is wasted in the form of heat, and comprehensive utilization of waste heat can achieve energy saving. For example, by introducing water into hot water supplies such as bathrooms, energy can be reused. In a closed cooling water system, methods such as increasing the area of the circulating water pool can be used to speed up the cooling of hot water, but the amount of cooling water should be controlled to avoid increasing the energy consumption of the circulating water pump.
.
Reactive power compensation saves energy
. Air compressors usually use asynchronous motors, and the power factor of asynchronous motors is relatively low, mostly between
and increases with changes in load. The amplitude changes and the energy loss is large.
. Reactive power compensation is to improve the power factor and reduce energy loss under the premise of normal operation of the motor. Installing a power capacitor at the power receiving end can effectively improve the power factor, especially suitable for low-voltage medium-sized motors that often operate continuously.
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Various frequency speed regulation and energy saving
. Frequency conversion speed regulation and energy saving realizes motor speed regulation by installing a frequency converter between the power grid and the motor to change the voltage and motor frequency. The frequency converter is used to control the speed of the air compressor to adjust the energy to meet the needs of light-load operation and match the exhaust volume with the air consumption.
. It has been proven through practice that the use of frequency conversion speed regulation method can improve the working efficiency of air compressors under light load operation, reduce the energy consumption of air compressors, and create better economic benefits for enterprises. This system controls the output pressure, connects the feedback signal to the frequency converter, and then compares it with the given signal. After adjustment, the comprehensive signal is sent to the input given terminal, and the motor speed and power are adjusted according to the pressure change. .
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Multi-unit group control energy saving
. In situations where the gas consumption is large and the gas load fluctuates greatly, it is difficult to use a single large-capacity air compressor to meet the needs of gas volume adjustment, and often Use multiple air compressors. Multi-unit group control technology is one of the effective methods to achieve energy saving under the operating conditions of multiple air compressors. It selects the required machines and number according to the actual air consumption, eliminates unnecessary waste, and has significant energy saving effects.