What are the main aspects of air compressor energy waste? In the process of using air compressors, there is the phenomenon of energy waste, and the main manifestations of energy waste are large leakage, configuration and operation only for the purpose of maintaining pressure, unreasonable supply pressure, low power of air gun nozzles, waste of gas for equipment, low awareness of gas cost among workers on site, and so on. Among these problems, leakage accounts for the largest proportion, and the poorly managed factories may even be as high as 50%.
Sometimes there are 20,000 leaks in an auto assembly plant, of which more than 90% of the leaks come from aging or broken parts in the use of equipment. What's particularly serious is that site managers far underestimate the damage caused by leaks. For example, a small 1mm diameter hole in a gas pipe caused by a welding slag in an automotive spot welding station results in an annual loss of about 3,525 kWh of electricity, which is almost equivalent to the annual household electricity consumption of two families of three. Strengthening awareness of leak loss and popularizing leak detection and prevention means are the focus of current efforts. At present, some domestic enterprises have started to use leak detectors and leak scanning guns to check and plug leaks, and have achieved some results.
The reasonable configuration and reasonable operation of screw compressor is very important to save electricity. Usually, in order to make the output pressure fluctuation small, many compressors use the suction valve adjustment method. In this way, 70% of the rated power is consumed even without air supply, which is a serious waste. For this reason, measures such as the introduction of variable frequency control and the use of expert control systems for compressor groups have been effective in reducing power. These measures are largely ignored in the actual operation of the plant, and pressure assurance is the only requirement for compressor management in most plants.
In addition, the supply pressure of screw air compressors is sometimes 0.2 to 0.3 MPa higher than the required pressure on site due to uncertain pipeline pressure loss and the existence of flow peaks in equipment start-up, which is very wasteful. Sometimes also for a few high pressure requirements of the equipment, and the entire air supply pressure is adjusted upward, which is extremely unreasonable in the configuration of energy use, not a wise move. All kinds of problems, indicating that the current use of compressed air systems in the gas waste is relatively serious.
Statistics show that the leakage of compressed air systems in general can be as high as 30 to 50%, better management of the factory or new plant about 10 to 30%, the acceptable range of about 5 to 10% of the common leak points in the compressed air system are; air compressor internal, storage tanks, dry. Operators, pipelines, valve parts, joints, welding points, air-using equipment, etc. Users of compressed air systems larger leak points are easier to observe. Usually the electricity consumed by compressed air system accounts for about 20~30% of the electricity used by enterprises, among which the air compressor set is the main source of electricity consumption, so reducing the electricity consumption of air compressor is the main key to energy saving of air pressure system.
The above is about the main performance of air compressor energy waste in which aspect is introduced to this, 96% of the energy consumption of the air compressor system is the power consumption of industrial compressors. This shows that we need to improve the energy use efficiency of compressed air system while adjusting the economic structure of industry. Take reasonable and effective energy-saving measures, you can achieve 30% or even higher energy-saving effect.
