Application solution for energy-saving engineering of air compressors in mechanical factories

2024/12/19 20:54:14

1、 Application scenario analysis

Mechanical manufacturing factories usually have a large number of pneumatic equipment, such as CNC machine tools, pneumatic fixtures, painting equipment, etc., which have a high demand for compressed air and complex gas requirements. Air compressors need to run for a long time to meet production needs, and traditional air compressor systems often have problems such as high energy consumption and unstable pressure, which affect production efficiency and product quality.

2、 Energy saving engineering solutions

Optimization of Air Compressor Selection

According to the peak and valley gas consumption in each production area of the factory, multiple air compressors of different specifications are used in combination for operation. For example, configuring a large fixed speed air compressor as the basic gas supply equipment to meet most of the stable gas demand; Equip several small variable frequency air compressors to flexibly supplement according to real-time gas consumption changes in different production processes. This can avoid the situation of large horses pulling small cars and improve overall energy utilization efficiency.

Choose high-efficiency and energy-saving air compressors that use advanced compression technology and high-efficiency motors, which can reduce energy consumption by 10% -20% compared to traditional air compressors.

Installation of intelligent control system

Introduce an intelligent monitoring and control system for air compressors to monitor the operating parameters of each compressor in real-time, such as pressure, flow rate, temperature, energy consumption, etc. Through intelligent algorithms, the start stop and load rate of the air compressor are automatically adjusted according to the actual gas usage situation, ensuring that the air compressor always operates at the optimal efficiency point. For example, when the gas demand in a certain production area decreases, the system automatically reduces or stops the operation of some air compressors; When the demand for gas suddenly increases, quickly start the backup air compressor and allocate the load reasonably.

Implementing remote monitoring function, management personnel can check the operating status of the air compressor system anytime and anywhere through mobile phones or computers, timely detect and handle faults, and reduce downtime.

Waste heat recovery and utilization

The large amount of waste heat generated by the operation of air compressors in mechanical manufacturing factories can be recovered through heat exchangers. The recycled hot water can be used for heating in the workshop, supplying hot water for employees' daily life, or heating in the production process, such as preheating the water tank before cleaning parts. This not only reduces the factory's consumption of other energy sources (such as gas, electricity, etc.), but also realizes the secondary utilization of energy, further improving the comprehensive energy utilization efficiency.

Pipeline system optimization

Conduct a comprehensive inspection and optimization of the compressed air pipeline system in the factory. Reduce the resistance components such as bends and reducers in pipelines, and use pipeline materials with smooth inner walls and low resistance to reduce the pressure loss of compressed air during transportation. According to the gas demand of each production area, plan the pipeline layout reasonably to ensure stable and uniform gas supply pressure. At the same time, regular leak detection and repair of pipelines should be carried out to avoid energy waste caused by leaks.

3、 Energy saving effect estimation

Through the implementation of the above energy-saving engineering solutions, it is expected that the energy consumption of the air compressor system in mechanical manufacturing factories can be reduced by 25% to 35%. At the same time, stable gas supply pressure will improve the operational efficiency of pneumatic equipment, reduce equipment failure rates, and thus increase overall production efficiency by about 5% -10%. The waste heat recovery and utilization system can meet some of the heating and hot water needs of the factory, saving about [X] million yuan in other energy costs annually.