Ingersoll Rand air compressor tells you - the truth is amazing! It is terrible to leak the compressed air system.
Views : 1601
Author : Runningway
Update time : 2019-03-29 09:45:40
In the current compressed air system, energy waste is mainly manifested by large leakage, compressor configuration and operation only for pressure keeping, unreasonable supply pressure, nozzle inefficiency, waste of equipment gas, and low awareness of on-site workers' gas cost. And other issues.
In the case of leakage, the leakage in the factory usually accounts for 10% to 30% of the gas supply, and the factory with poor management may even be as high as 50%. Sometimes there are 20,000 leaks in a car assembly shop, of which more than 90% of the leaks come from aging or damage to the parts in use. What is particularly serious is that field managers far underestimated the losses caused by the leak. For example, a leaking hole with a diameter of 1 mm in the air pipe at a supply pressure of 0.7 MPa causes an annual loss of up to about 3,525 kWh, which is almost equivalent to the annual household electricity of two family of three, as shown in Table 2.
Proper configuration and proper operation of the compressor is very important to save electricity. Usually, in order to make the output pressure fluctuation small, many compressors adopt an intake valve adjustment mode. In this way, if there is no air supply, it still needs to consume 40% to 70% of the rated power, and the waste is more serious. To this end, the introduction of variable frequency control, number of units control, the use of air compressor room energy-saving monitoring system and other measures to reduce power is very effective. These are largely ignored in the actual operation of the plant, ensuring that pressure is the only requirement for compressor management in most plants.
In addition, due to the uncertainty of the pipeline pressure loss, the equipment starts to have a peak flow rate, etc., the supply pressure of the compressor is sometimes 0.2MPa to 0.3MPa higher than the required pressure on site. For every 0.1 MPa increase in the end equipment, the power consumption of the compressor is increased by 4% to 8%, resulting in huge energy waste. Sometimes, for a small number of pressure-demanding equipment, and the entire increase in gas supply pressure, this is extremely unreasonable in the energy use configuration, it is not wise.
The nozzles are widely used in air jet loom, finishing and machining of manufacturing and machining, and their gas consumption reaches 50% of the total gas supply in some industries. Generally, during the use of the nozzle, there are problems that the gas supply pipe is too long, the supply pressure is too high, and the straight pipe copper pipe is used as a nozzle. In addition, on-site personnel can easily expand the nozzle nozzle and increase the supply pressure in order to pursue large impact forces, resulting in a large waste of gas, as shown in Figures 8 and 9.
In addition, the phenomenon that the gas is unreasonable in the pneumatic equipment is also prominent, for example, the gas back pressure detection for determining whether the workpiece is stuck or not, and the vacuum generator gas supply, etc., which are not working or uninterrupted gas supply. In particular, a gas used for stirring, such as a chemical liquid tank, or a shaped gas in the tire manufacturing, is generally used from a high pressure reduction of 0.7 MPa to a pressure of 0.1 MPa to 0.2 MPa, and waste is painful. Grasping the actual required pressure and air consumption of the equipment from the process is a prerequisite for rationalizing the gas consumption of the equipment. The waste due to unreasonable gas consumption of the equipment is estimated to be an average of 20% of the gas supply.
All of the above problems indicate that the current gas consumption in the use of compressed air systems is more serious. The energy-saving renovation measures for gas-using equipment are:
1 Using a new pneumatic nozzle energy-saving device and a pulse air gun, the nozzle starts to purge when the workpiece is in place;
2 When the workpiece is in place, the vacuum generator starts to supply air;
3 high energy-consuming pneumatic equipment changed to electric equipment (process agitation);
4 large cylinders change two energy-saving cylinders;
5 Compressed air meets the demand pressure of the equipment, and increases the amount of gas used for buffering in a suitable gas storage tank;
6Professional pneumatic equipment is used in specific industries, such as the special throttle valve for shelling cylinders promoted by the electrolytic aluminum industry.
Therefore, as long as a detailed investigation of the compressed air system, clear problems, and reasonable and effective energy-saving measures, the entire system can achieve energy savings of 20% or higher.
Login 
Inquiry List
