1. Add cooling and dehumidification devices
During the process of compressing air, steam and other particulate matter mixed in the gas will also be compressed in this process. The compressed steam and various particulate matter will corrode the gas transmission pipeline and various node control devices, affecting their performance, and will also increase the transmission noise, resistance and energy consumption. In addition, some particulate matter will also be adsorbed on the surface of the dust removal and filtration device, which will increase the back pressure of the pipeline, and the operation quality of the gas-using equipment will also be affected.
In order to effectively avoid the above problems, the input gas can be dried and purified by adding a dehumidification device, and the effect is more significant. In this process, the refrigeration function of the cold dryer can be used to condense the steam mixed in the gas and convert it into liquid water that can be discharged by the automatic drainer, thereby reducing the possibility of corrosion of various components of the air compressor. At the same time, the cold dryer can also accelerate the condensation of oil mist, causing the water vapor and dust particles carried in the input gas to condense with the oil mist, so that they can be discharged together.
In order to avoid excessive gas temperature and increase energy consumption, a gas storage tank can also be installed at the rear end of the air compressor, and used in conjunction with the cold dryer to further improve the cooling and dehumidification effect and reduce energy consumption.
2. Strengthen pressure flow control
In actual work, the screw air compressor system needs to provide compressed air for multiple gas-using equipment, but the gas volume and specific gas consumption time required by each equipment are different, which will affect the stability of the system pressure flow and easily cause pulse fluctuations. For this kind of pulse fluctuation effect, the pressure flow controller can be used to stabilize the pressure load of the pipeline network when the air compressor is running, so that the air compressor can maintain efficient operation without adjusting the system pressure, and the pressure of the entire system is in a relatively stable state, and the energy loss is significantly reduced. With the assistance of the pressure flow controller, the compressed air system can maintain a stable air supply pressure, and the pressure adjustment range will be more precise, which can minimize the occurrence of pulse fluctuations, thereby avoiding energy loss caused by abnormal pressure fluctuations. At the same time, it can also improve the stability and reliability of the system air supply.
3. Regular maintenance of the pipeline network
During the operation of the screw air compressor, the power consumption can increase by 7% for every 0.1MPa increase in exhaust pressure. It can be seen that strict control of exhaust pressure is an effective measure for air compressor energy saving. The change of exhaust pressure has a lot to do with the layout of the transmission pipeline network and the leakage of the pipeline network. The overall performance of the pipeline network will gradually decline with the continuous accumulation of running time. Therefore, it is necessary to regularly maintain the pipeline network after the air compressor is put into use to reduce the transmission loss of the pipeline network as much as possible. When maintaining the pipeline network, it is necessary to conduct a full network inspection from an overall perspective, and focus on the prevention of gas leakage. In this link, the traditional soapy water detection method can be used to determine whether there are pores in the pipeline network and the specific location of the pores, and deal with the problem points in time after locking them.
At present, intelligent pipeline network detection equipment can be used for air compressor users. This intelligent pipeline network detection equipment can complete safety detection faster and more accurately, effectively detect the leakage location, and is more efficient than the traditional soapy water detection method, and saves labor costs. Regular maintenance of the pipeline network can eliminate the various effects that gas leakage may have on the actual operating efficiency of the air compressor volume flow meter, thereby reducing the energy loss caused by it. In addition, pipeline network maintenance can also help air compressor users to find worn pipelines in time. In order to improve the transmission efficiency, alloy pipelines with smoother interiors and better overall performance can be used to replace worn pipelines.
4. Waste heat recovery
The energy input during the operation of the screw air compressor can be roughly divided into two categories: one is useful work, which generally refers to the heat that can increase the potential energy of compressed air; the other is useless work, which generally refers to all the heat generated when the potential energy of compressed air is increased. A small part of the energy will be dissipated through the surface of the equipment and cannot be recovered, while the rest of the heat will be lost with the cooling water or cooling air duct. These lost heat can be reused through waste heat recovery treatment, which is an important manifestation of effective energy saving of air compressors.
For screw air compressors, waste heat recovery can be achieved in two ways: one is to recover the waste heat of the cooling exhaust duct. When this method is used, two electric air valves can be installed near the outdoor exhaust port and the heating workshop exhaust port. At the same time, a temperature sensor is installed in the heating workshop. If the workshop temperature does not reach the established parameters, the electric air valve close to it can be opened, and the other air valve needs to remain closed to discharge the cooling hot air into the room. When the workshop temperature exceeds the established parameters, the reverse operation can be performed. This skill measure does not require too much investment and is simple to operate. It can not only achieve the purpose of environmental protection and energy saving, but also save the processing cost of the user unit. The second is to recycle the waste heat of cooling water. When the air compressor is performing compression operations, it usually generates a lot of high-temperature heat. In order to improve the compression processing efficiency, most of this heat will be discharged with the cooling water, which invisibly increases the energy consumption of the air compressor. As we all know, tap water will heat up after absorbing enough heat energy, and the hot water generated during the compression process can play a surplus value in workshop heating and other aspects, and can also be used as domestic water. After recycling, it can effectively solve the problem of water resource waste in the compressed air process, and the heat generated during compression will also be fully utilized.
5. Centralized control
For large-scale air compressor users, traditional manual control is difficult to effectively meet the use requirements of multiple air compressors. At this time, it is necessary to use centralized control to regulate the operating status of the air compressor group and optimize resource allocation. In order to obtain better control effects, it is necessary to dynamically control based on the changes in the demand of the unit's gas-using equipment and the actual operating conditions of each air compressor, such as start and stop, loading and unloading, etc. In this process, it is necessary to ensure the reasonable operation of the system and the stability of the pipe network pressure, and try to avoid pressure fluctuations. In the centralized control mode, the air compressor group can achieve efficient operation, and the system control accuracy is higher, the response speed is faster, the control range is wider, the performance is more stable, and the problem of increased energy consumption caused by increased exhaust pressure can be avoided.
KAPA has been focusing on screw air compressor solutions for 20 years.
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Website: https://www.kapaac.com/
