What is the main manifestation of air compressor energy waste?

What is the main manifestation of the energy waste of air compressors? During the use of air compressors, there is a phenomenon of energy waste, and energy waste is mainly manifested in large leakage, configuration and operation only for pressure maintenance, and unreasonable supply pressure , Air gun nozzle power is low, equipment gas is wasted, on-site workers are not aware of the cost of gas consumption, and so on. Among these problems, leakage accounts for a large proportion, and poorly managed factories may even reach as high as 50%.

Sometimes there are 20,000 leaks in an automobile assembly workshop, and more than 90% of the leaks come from the aging or damage of the parts in use. What's more serious is that the on-site management personnel far underestimated the losses caused by the leakage. For example, a small hole with a diameter of 1mm caused by a welding slag in an automobile spot welding station can cause a loss of about 3,525 kilowatt-hours of electricity every year, which is almost equivalent to the annual household electricity consumption of two three-person households. Strengthening the awareness of leakage loss and popularizing leakage detection and prevention methods are the current priorities. At present, some domestic companies are beginning to use leak detectors and leak point scanners to check leaks and plug leaks, and have achieved some results.

Reasonable configuration and reasonable operation of screw air compressors are very important to save electricity. Generally, in order to make the output pressure fluctuation small, many compressors adopt the suction valve adjustment method. In this way, 70% of the rated power is still consumed when there is no air supply, and the waste is more serious. For this reason, measures such as the introduction of variable frequency control and the use of compressor group expert control systems have been very effective in reducing power. These are basically ignored in the actual operation of the factory, and guaranteeing pressure has become a requirement for compressor management in most factories.

In addition, due to the uncertainty of pipeline pressure loss and the flow peak during equipment startup, the air supply pressure of the screw air compressor is sometimes 0.2 to 0.3 MPa higher than the on-site required pressure, which is very wasteful. Sometimes, for a few devices with high pressure requirements, the entire air supply pressure is increased. This is extremely unreasonable and unwise in terms of energy usage configuration. All kinds of problems indicate that the waste of air in the current use of compressed air systems is relatively serious.

Statistics show that the leakage of compressed air systems can generally be as high as 30~50%, about 10~30% for better-managed factories or new factories, and the acceptable range is about 5~10%. Common leaks in compressed air systems are; The inside of the air compressor, the gas storage barrel, the dryer, the operating machine, the pipes, the valves, the joints, the welding points, the gas equipment, etc. It is easier for users to observe the larger leak points of the compressed air system. Usually, the electricity consumed by the compressed air system accounts for about 20-30% of the electricity used by the enterprise, and the air compressor is the main source of electricity consumption. Therefore, reducing the power consumption of the air compressor is the main key to energy saving in the air compressor system.

The above is about the main performance of air compressor energy waste. 96% of the energy consumption of the air compressor system is the power consumption of industrial compressors. This shows that while adjusting the industrial economic structure, we also need to vigorously improve the energy efficiency of the compressed air system. Taking reasonable and effective energy-saving measures can achieve 30% or even higher energy-saving effects.